Structure of battery cells, battery modules or battery pack integrated with liquid cooling channels

Abstract

when Electric Vehicle are "Ultra Fast charged" or in case it needs extreme Power output, the drive Battery will heat up significantly. if the heat cannot be removed quickly enough, the heat can lead to degradation of Battery performance and potential risk of thermal Runaway. Furthermore At cold wheather under 0C degrees most lithium battery cells cannot be fast charged, risk of lithium (Li) plating and Battery in shortage range. The present Invention is plurality of Battery Cells Casing together with Liquid Channels constructed and integrated into Battery Module Housing or into Battery Pack Housing. This innovative solution enhance Liquid cooling and Heating of Battery Cells efficiently at optimal condition.

Description

[0001] KLIB-DES-2024-002 PCT / IB2024 / 000002

[0002] Description

[0003] Title of Invention : Structure of Battery Cells, Battery Modules or Battery Packs integrated with Liquid Cooling Channels

[0004] Technical Field

[0005] [1] The Present Invention relates to Structure of plurality of Battery Cells Casing, Battery Module and / or Battery Pack Housing that can be implemented by manufacturers in order to improve cooling of New Energy Vehicle Battery.

[0006] Background Art

[0007] [2] The Lithium battery commonly are used in the power source of the vehicle, which connected in series and parallel to form a battery module. When Electric Vehicle are “ Ultra Fast Charged ” or in case of extreme Power output, the drive Battery heats up significantly, if the heat cannot be removed quickly enough, In this case heat can lead to degradation of Lithium Battery performance and potential risk of thermal Runaway.

[0008] [3] Furthermore most lithium battery cells cannot be fast-charged when they are less than 5C degrees, risk of lithium (Li) plating and low charging speed. At cold wheather under 0C degrees, Battery cells need preheating for better performance before starting operation.

[0009] [4] State of the art to keep Battery working in Range Temperature are connected Battery Pack to chiller allowing Cooling fluid to extract heats from the battery. Since the liquid is circulating, it drives the heat away into the heat exchanger. That is where the liquid gets cool again, and the process is repeated to extract heat consistently

[0010] [5] Battery thermal management system makes power battery work within the appropriate temperature range to maintain its best use state. Because batteries are only manufactured to work between certain temperature extremes, they will stop working if there is no cooling system to keep it in a working range. For safety and performance of Battery Cell, Cooling systems need to be able to keep the battery pack in the temperature range of about

[0011] Page 1 / 20 KLIB-DES-2024-002 PCT / IB2024 / 000002

[0012] 20-40 degrees Celsius, as well as keep the temperature difference within the battery pack to a minimum.

[0013] [6] Improvements in design heat dissipation system of plurality of Battery cells are key to achieve faster charging speeds, Higher Power EV, ensuring safety and Performance. This is Challenge of battery Module and Battery Pack design to ensure an effective cooling system.

[0014] [7] Another problem in state of the art technology for manufacturing Power Battery for Electric vehicle are The Production process quite complex and requires multiple processes, from a battery cell to battery module and then to a battery pack.

[0015] Summary of Invention

[0016] [8] The High Voltage Power Battery consisting of Plurality of Battery Cells is Energy source for Electric Vehicle and an important indicator that affects its Performance. During charging and discharging process, The Battery will lead to a certain heat, which will cause increasing temperature that will affect many working characteristics parameters of the Battery, such as Voltage, available capacity, charging and discharging efficiency, and battery life.

[0017] [9] The liquid cooling system has unique advantages in meeting the working temperature requirements of the power battery between the two circuits of cooling and heating. This new Innovative approach is not only useful for Battery Cell Cooling but Also for Battery Cell Heating.

[0018]

[0010] State of the art Battery Cell Casing is Constructed and manufactured as individul cell. It is not Integrated with Battery Module Structure or Battery Pack Structure. Then Cooling Unit constructed separately from Cell Casing commonly using Cooling Plate.

[0019]

[0011] at Present Invention As innovative step, Plurality Battery Cell Casing together with Cooling Channel constructed and integrated in Battery Module Housing or in Battery Pack Housing. This innovative Structure provides plurality of battery cells casing having directly surface contact with cooling medium that dissipates the heat effectively in Battery Cell Module or in Battery Pack resulting better thermal control for maintaining a battery pack

[0020] Page 2 / 20 KLIB-DES-2024-002 PCT / IB2024 / 000002 in the optimal temperature range and uniformity to ensure the performance and life cycle of the battery system.

[0021] Technical Problem

[0022]

[0012] State of art Cell Battery Cooling in Battery Pack Electric Vehicle is Passive and active Cooling by Air Flow from Cabin to Battery Pack. The Cooling system using Air flow has limitations about heat carrying capacity, heat transfer efficiency and less efficient because of cabin need more Energy. More Efficient than Air Cooling are Liquid cooling that have better heat dissipation and Efficientcy.

[0023]

[0013] State of the art liquid cooling are InDirect Cooling that use Cooling Plates that have contact surface directly with Battery Cell Casing. But this Solution Less Efficient, more small Parts to Manufacture, High Assembly Cost and less reliable due to vibration in Vehicle.

[0024]

[0014] Another Liquid cooling is Direct Cooling that Submerged Battery Cell in Dielectric fluid (Immersion Cooling System). In this system there is direct Contact fluid with casing of battery cell. Immersion cooling systems produce homogeneous battery temperatures and can transfer high heat flows. Disadvantage of Immersion Cooling System are However, the weight of the fluid, flow control, space utilization are significant challenges and mass production is also quite difficult.

[0025]

[0015] Another problem state of the art technology are The Production process from a battery cell to battery module and then to a battery pack also quite complex and requires multiple processes.

[0026] Solution to Problem

[0027]

[0016] The present Invention are plurality of Battery Cells together with Cooling Channels constructed and integrated into Battery Module Housing and / or in Battery Pack Housing. This Structure accommodate Cooling Liquid direct contact with Battery Cell Walls at all sides except Electroda Terminal side. This Innovative Design Structure can accommodate Direct Cooling without Submerging Electroda Terminal in Dielectric fluid as adopted by Immersion Cooling System. This Innovative steps is not only aplicable for Cell Battery

[0028] Page 3 / 20 KLIB-DES-2024-002 PCT / IB2024 / 000002

[0029] Cooling but Also for Battery Cell Heating that needed during fast charging of Electric Vehicle at low temperature in Cold Weather.

[0030]

[0017] By Solution of present Invention, plurality of Battery Cell Casing are Constructed and integrated with cooling channel in Battery Module and / or Battery Pack Housing. Main Advantage of present invention is better Battery Cell Cooling Characterized that All side of Battery cell walls having direct Contact with Cooling Water Except Terminal side. Beside that The Present Invention will also reduce EV battery costs by removing Individual Cell battery casing manufacturing and minimize assembly process in Battery Module and Battery Pack.

[0031]

[0018] This Solution make more Efficient battery Cell cooling or Heating, Rigid structure between battery cell, Less Parts, More Efficient production and can achieve cost reduction to Manufature Battery Pack.

[0032]

[0019] The structure of Plurality of Battery cells constructed and integrated with liquid channel can be Manufactured by Extrusion process by restraining cover plate at two end side of Extrusion or can be process directly by Aluminum Casting for example low pressure casting.

[0033]

[0020] This Solution make more Efficient battery Cell cooling and Heating, Rigid structure between battery cell, Less Parts, More Efficient production and can achieve cost reduction to Manufature Battery Pack.

[0034]

[0021] The cooling performance of the power battery is the core of thermal management design, and the cooling performance of Battery Module will directly affect the efficiency and performance of new energy vehicles.

[0035] Advantageous Effects of Invention

[0036]

[0022] Advantages Direct Cooling with Integrated multiple Cell with Cooling Channels in Battery Module or / and Battery Pack are :

[0037]

[0023] The heat exchange area is expanded to Maximal Condition The large- surface cooling contact area of the battery accommodates Better Dissipation Heat and Better Thermal Control.

[0038]

[0024] The Battery Module and / or Battery Pack more reliable, less Components, Structure between Cell more Rigid .

[0039] Page 4 / 20 KLIB-DES-2024-002 PCT / IB2024 / 000002

[0040]

[0025] The Present Invention reduce EV battery costs by simplifying structure design and Process that make manufacturing Cost lower (Direct Manufacture Battery Cell in Module or in Battery Pack by removing individual Cell Manufacturing), lower investment to Manufacture Battery Module or Pack while at the same time extending battery lifecycles by improving Battery Cells Cooling effectively and minimizing hot spots within EV batteries.

[0041]

[0026] This design housing of batteries can achieve thermal stability and thermal safety of the full chemical system, thus adapting to material upgrades with higher energy density.

[0042]

[0027] The present invention increase cooling area effectively, adapts to the launch of the next 800V High Voltage platform models standard by Electric Vehicle companies.

[0043]

[0028] With the increasing performance of Battery cells and faster charging and discharging speed, liquid cooling Technology is becoming one of the mainstream new Technology for vehicle manufacturers for reducing the cost of electric vehicle (EV) batteries. This is one of the most important factors for making electric vehicles more affordable for consumers.

[0044]

[0029] This present invention will reform In the state of the art battery cell and module manufacturing process. Piping for Liquid of Battery Module or Battery Pack more simple.

[0045]

[0030] The present invention is applicable also for cooling and heating Electric Energy Storage like Supercapacitor or Ultracapacitor. Supercapacitor, also known as electrochemical capacitors or double-layer capacitors, are devices that store energy by polarizing electrolytes. Compared to traditional batteries and capacitors, supercapacitors have advantages such as faster charging, higher discharge efficiency, longer cycle life, and environmental friendliness. Although Supercapacitor have broad application prospects in the energy field like Electric Vehicle, they still face some challenges and issues in practical applications because of low Energy storage Capacity compared to Lithium Ion Battery. Supercapacitor lifespan is also shortened by any detrimental environmental extremes (i.e. hot or cold temperatures). Consequently, most of the time, supercapacitors are equipped with a cooling system when

[0046] Page 5 / 20 KLIB-DES-2024-002 PCT / IB2024 / 000002 temperature may exceed approximately 65 °C . Super capacitor Normally is installed as standalone or Multi Cell depends on Application.

[0047] Brief Description of Drawings

[0048]

[0031] [fig.l] Fig.l Shows Battery Module Embodiment, consisting of : Fig.lA illustrates exemplary the Embodiment architecture of Battery Module having 5 Battery cells in exploded isometric view. Fig. IB illustrates embodiment of Assembly Battery Module 100.

[0049]

[0032] [fig.2] Fig.2 Shows details of Battery Module Embodiment Parts in isometric view. Consisting of : Fig.2A shows Battery Module 100 in exploded isometric view. Fig.2B shows front parts of Battery Module. Fig.2C (Fig.2C-l and Fig.2C-2) show backparts of Battery Module.

[0050]

[0033] [fig.3] Fig.3 consisting of : Fig.3A Shows Embodiment of Battery Module Housing 10. Fig.3B-l shows detail of Battery Cell Casing from 11-1 to 11-5, Rib Divider 12 and Rib Separator 13 and Fig.3B-2 shows detail of Cooling Channel from 14-1 to 14-6, in Front View (X-Z Plane).

[0051]

[0034] [fig.4] Fig.4 consisting of : Fig.4A shows Embodiment of Battery Module 100. Fig.4B illustrates the Liquid Flow inside front part of Battery Module, Fig.4C illustrates the Liquid flow inside Backpart of Battery Module in Top View (X-Y Plane) and inlet of Liquid Tube 42 and outlet of Liquid tube 32.

[0052]

[0035] [fig.5] Fig.5 consisting of : Fig.5A shows Embodiment of Battery Module 100. Fig.5B illustrates the Liquid Flow inside frontpart of Battery Module, Fig.5C illustrates the Liquid Flow inside backpart of Battery Module at side channel 1 (14-1) by Side View (Y-Z Plane) and shows inlet of Liquid Tube 42.

[0053]

[0036] [fig.6] Fig.6 consisting of : Fig.6A shows Embodiment of Battery Module 100. Fig.6B-l illustrates the Liquid Flow inside front part of Battery Module through partial sectional of Isometric View. Fig.6B-2 as Fig.6B-l illustrates the Liquid Flow inside front part of Battery Module wherein Cover Plate 31 removed. Fig.6B-3 as Fig.6B-2 illustrates the Liquid flow wherein Lids 22 and Electrode Terminal 21 removed.

[0054] Page 6 / 20 KLIB-DES-2024-002 PCT / IB2024 / 000002

[0055]

[0037] [fig.7] Fig.7 consisting of : Fig.7A shows Embodiment of Battery Module 100. Fig.7B-l illustrates the Liquid Flow inside front part of Battery Module through partial sectional of X-Y-Z Plane. Fig.7B-2 as Fig.7B-l, illustrates the Liquid Flow at Side channel, Upper Channel and lower channel inside front part of Battery Module wherein Cover Plate 31 and Lid 22 of cell 1, 3 and 5 removed.

[0056]

[0038] [fig.8] Fig.8 consisting of : Fig.8A shows Embodiment of Battery Module 100. Fig.8B-l illustrates the Liquid Flow inside back part of Battery Module through partial sectional of isometric view. Fig.8B-2 as Fig.8B-l, illustrates the Liquid Flow at Side channel, Upper Channel and lower channel and rear face inside back part of Battery Module wherein Cover Plate 41 removed.

[0057]

[0039] [fig.9] Fig.9 illustrates the architecture of the invented Battery Module embodiment in case of Terminal Electroda 21 plus (+) and minus(-) in different Position (Opposite side each other). Consisting of : Fig.9A exploded view of Battery Module Embodiment. Fig.9B shows front Lid 22 and Electrode Terminal 21 of front part of Battery Module. Fig.9C shows Cover Plate unit 40, Rear Lid 24 and Electrode Terminal 21 of Backparts of Battery Module.

[0058]

[0040] [fig.10] Fig.10 illustrates the Liquid Flow inside Rear of Battery Module through partial sectional View (Y-X-Z Plane) refer to Terminal Electroda plus (+) and minus(-) in different Position (Opposite each other) consisting of : Fig.lOA shows Embodiment of Battery Module 100. Fig.l0B-l illustrates the Liquid Flow inside back part of Battery Module through partial sectional View. Fig.lOB-2 as Fig.lOB-1, illustrates the Liquid Flow at Side channel, Upper Channel and lower channel inside back part of Battery Module wherein Cover Plate 41, Rear Lid 24 and Electrode Terminal 21 for cell 1 and 5 removed.

[0059]

[0041] [fig.11] Fig.11 illustrates alternative of variant embodiment if front Cover Plate unit 30 and Lid of Battery Cell 22 integrated in same plate. Consisting of : Fig.llA shows Embodiment of Battery Module 100 in Exploded isometric view. Fig.llB-1 Detail of front parts of Battery Module in case Cover Plate unit 30 and Lid 22 separate. Fig.llB-2 detail of front part of Battery Module in case Cover Plate unit 30 and Lid 22 integrated in one Plate 25 or device.

[0060] Page 7 / 20 KLIB-DES-2024-002 PCT / IB2024 / 000002

[0061]

[0042] [fig.12] Fig.12 consisting of Fig.l2A and Fig.l2B, illustrates embodiments of combination several modules to form Battery Pack.

[0062]

[0043] [fig .13] Fig.13 illustrates Front View (Fig.l3A) and Rear View (Fig.l3B) alternative of Housing Embodiment variant of 2 Battery Cells integrated with Micro Liquid Channel tube as result of Multi Micro Port Exstrusion(MPE). Liquid Channel in this embodiment is as Round Tube. Fig.l3A and Fig.l3B shows also Groove 19 by Process Machining (Milling) by End Milling Cutter to configure Rib divider 12 and Rib separator 13 after process cutting Extruded Aluminum by Table Band Saw Machine.

[0063] Details Description of Embodiments

[0064]

[0044] The foregoing examples and illustrative implementations of various embodiments have been provided merely for explanation and are in no way to be construed as limiting of the embodiments disclosed herein. While the embodiments have been described with reference to various illustrative implementations, drawings, and techniques, it is understood that the words, which have been used herein, are words of description and illustration, rather than words of limitation. Furthermore, although the embodiments have been described herein with reference to particular means, materials, techniques, and implementations, the embodiments are not intended to be limited to the particulars disclosed herein; rather, the embodiments extend to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims. It will be understood by those skilled in the art, having the benefit of the teachings of this specification, that the embodiments disclosed herein are capable of modifications and other embodiments may be effected and changes may be made thereto, without departing from the scope of the embodiments disclosed herein.

[0065]

[0045] Hereinafter, various of embodiment of present disclosure will be described in detail with reference to accompanying drawings. Portions that are irrelevant to the Description will be omitted to clearly describe the present disclosure. Further in the drawings, size or thickness and shapes of each elements are arbitrarily illustrated for convenience of description, It is exaggerated for clarity not for limitations.

[0066] Page 8 / 20 KLIB-DES-2024-002 PCT / IB2024 / 000002

[0067]

[0046] The Battery Cell consists of a positive electrode, a negative electrode, a separator, and an electrolyte. The positive and negative electrodes are the two polar ends of the battery cell (Cathode and Anode). A diaphragm (separator) separates them. The positive and negative electrodes contain active materials and are usually the site of chemical reactions.

[0068]

[0047] A battery module is a unit assembled from multiple battery cells. Used to provide higher voltage and capacity. It is a component in the battery system, usually consisting of several battery cells, connectors, and Housing.

[0069]

[0048] A battery pack is an integral unit assembled from multiple battery modules. It is used to store and provide electrical energy. Battery pack Unit usually consists of several battery modules, connectors, battery management system (BMS), cooling system to control temperature, electrical interface, and Housing. In Battery Pack, Battery modules are connected in parallel or series to increase the battery system’s voltage, capacity and power.

[0070]

[0049] In this disclosure of embodiments, explanation Will be emphasized on relating to aspects of Liquid flow through Mechanical Structure of Battery module.

[0071]

[0050] The Liquid channel is functioned to flow Cooling liquid into and out of Battery Module Housing for absorbing the heat generated by Chemical Process in internal of Battery cell casing.

[0072]

[0051] Liquid cooling in this Embodiments as prior art uses a liquid coolant such as Water, a Refrigerant, or Ethylene Glycol to cool the battery, the liquid cooling system involves Pumps, Fans, Heat exchanger and other devices to actively extract and dissipate the heat from Cell to atmosphere that the function is state of the art technology not to explain in this description.

[0073]

[0052] In this disclosure of embodiments, Front side of the Battery Module is defined in which Electrode Terminal (Positive and Negative) exist that Refer to Fig.lA which Cover Plate Unit 30 is in front side of the Battery Module, meanwhile Cover Plate unit 40 is on the opposite side from Electrode Terminal that defined as Rear side.

[0074] Page 9 / 20 KLIB-DES-2024-002 PCT / IB2024 / 000002

[0075]

[0053] As shown in Fig.2B, it is enlarged display of Battery module in Front side, and in Fig.2C is enlarged display from Rear Side of Battery Module (Fig.2C-l and Fig.2C-2)

[0076]

[0054] In this Embodiments, the module consist of five battery cells prismatic form for simplifying. Refer to Fig. 3B front view , Prismatic Battery Cell Casing 11 consist of number 11-1 to 11-5 from Left to right side.

[0077]

[0055] In this illustration of Invention Refer to Fig.l to 8, Fig.ll, and Fig 12, which Electroda Terminal plus and minus (+ and -) at front side of Battery Module 100.

[0078]

[0056] Refer to Fig. 3, Ribs 12 and Ribs 13 are Normally thin, typically is designed into the geometry of a part to add internal support to walls and to form liquid Channels.

[0079]

[0057] In this embodiment, function of Ribs 12 as Channel divider that will divide one channel to be multiple channels or passages with same flow direction to maximize heat dissipation from Cell Casing. Meanwhile Function of Ribs 13 is as Channel separator that differentiate a multi channel with another multi channel or to close or open flow between a multi channel with another . In this module Housing, the Channel separator is functioned to separate between multi channel for making of difference of flow direction (opposite direction) between multi channel.

[0080]

[0058] In present invention of Structure, in Fig.l to 8, Fig.ll, and Fig.12, Heat dissipation Surface contact Area is maximized by arrangements of Liquid Cooling Channel in Left and Right side of Cell Casing 11, through Upper, Lower side channel as shown in Fig.3B (Fig.3B-l and Fig.3B-2) And also through Rear side of Cell Casing 11 as shown in Fig.8B-2.

[0081]

[0059] Front Cover Plate and Rear Cover Plate Can be Fixed in Module Casing by Lock Bolt 33 and 43 with additional Sealant Gasket or by others fastening . Cover Plates are functioned to arrange Water Flow intracell (inter channel in a Cell) and inter Cell (Inter Channel between Cell). Another alternative can be Fixed Permanently by Epoxy Bonding or Welding Process (Normally Laser Welding). As another alternative, Cover Plates Can be also casted integrated with Plurality of Battery cells and Multi Liquid channels as one unit

[0082] Page 10 / 20 KLIB-DES-2024-002 PCT / IB2024 / 000002

[0083] Casting by Low Pressure Casting. In this ilustrasion, the liquid goes to Battery Module through tube 42 positioned at rear cover plate Unit 40 of Battery Module as shown in Fig. 2C-2, Fig 4C and Fig.5C. Subsequently liquid flow at side channel 14-1 towards front position and because of front cover plate unit 30, at the end position, liquid turns to upper channel 15-1 and lower channel 16-1 of Battery cell casing 11-1 as shown in Fig.3B-2, Fig.4B, Fig.5B, Fig.6B and Fig.7B. Later on liquid flow inside upper channel 15-1 and lower channel 16-1 in the opposite direction than before, toward rear side of Battery module as shown in Fig.4B, Fig.4C, Fig.6B-3, Fig.7B-2 and Fig.8B-2. And Then liquid from upper side and lower side, at the end of rear position, because of Rear cover plate 40 and arrangements dimensions of Rib Separator 13, the Liquid will turn to side channel 14-2 of Battery cell as shown in Fig.4C and Fig.8B-2. Subsequently liquid will flow in liquid channel 14-2 in the opposite direction than before to frontside of Battery Module and at the end position because of cover plate 30, liquid will turn to Upper side channel 15-2 and lower side channel 16-2 of Battery Cell Casing 11-2. Subsequently liquid flow inside upper channel 15-2 and lower Channel 16-2 toward rear position of Battery cell Casing 11-2. Thereafter liquid will flow as previously to side channel 14-3 and so on . By the end at upper channel 15-5 and lower channel 16-5 the liquid will turn to last side channel 14-6 and will exit to outside Battery module 100 through tube 32 at Front cover plate unit 30 . By this technique the liquid goes to Battery Module through inlet tubes 42 flow through several channels that surround multiple cells Casing and exit through tube 32, This illustration is shown in Fig. 4B and Fig.4C in Upper View. By additional piping, the heat can be dissipated to another module or can be dissipated directly to atmosphere through radiator or a heat exchanger unit.

[0084]

[0060] Refer to Illustration of Fig.4, Fig.5, Fig.6, Fig.7 and Fig.8. shown that because of inlet in rear side and outlet at front side, Liquid in side channel 14 flows always towards front side from rear side. Meanwhile liquid in upper channel 15 and lower channel 16 always in same flow direction from front side to rear side. At Application position of inlet and outlet can be exchanged so that flow direction at side channel, Upper Channel and Lower Channel wil be opposite direction than above illustration.

[0085] Page 11 / 20 KLIB-DES-2024-002 PCT / IB2024 / 000002

[0086]

[0061] Meanwhile in Fig.9 and Fig.10, as alternative design Application, Electrode Terminal plus (+) can be positioned in front side of module and Electroda Terminal minus (-) can be positioned In rear side of module or vice versa (Opposite side each other). Positioning of plus minus Electrode Battery Terminal 21 depend on Electrical arrangements serial or paralel inter Cell (between battery cell) of connection design configuration and influenced also by dimension of Battery cells that outside of this disclosure. In Addition, because of plus and minus electrode terminal is in different side of module, Heat dissipation exist in side Channel 14 .Upper Channel 15, Lower Channel 16, but there is not Liquid Cooling in rear side of Cell Casing 18 as shown in Fig.lOB-2.

[0087]

[0062] In Fig.13 illustrates Front View and Rear View of Housing Embodiment of 2 Cells of Battery cells integrated with Micro Liquid Channel tube as result of Multi Port Exstrusion. Liquid Channel in this embodiment as Round Tube. In Fig.l3A as shown idea of Side Channel 14, Upper Channel 15, Lower 16 of Cell 1 and Cell 2 and Rib Divider 12 and Rib Separator 13. Cell 11-1 in left side cell 11-2 in right side. In Fig.l3B shows Rear View , Cell 11-1 in right side and cell 11-2 in left side. Fig.l3B shows Liquid Side Channel 14, Upper Channel 15, Lower Channel 16, Rib Devider 12 and Rib separator 13 as Pair than Fig.l3A. Fig.13 shows also Groove 19 by Process Machining (Milling) by End Milling Cutter to configure Rib divider 12 and Rib separator 13 after process cutting extruded Aluminum by Table Band Saw. Small End Milling Cutter for grooving available 1 - 6 mm, even also available for extrim small size known as Micro milling Cutter 0.2 - 0.9 mm by using material HSS or Carbide. After process cutting of Extruded Aluminum by Table Band Saw, facing surface is needed also by milling Cutter to ensure flatness and roughness of the surface before Laser welding of Cover Plates or Lids.

[0088] Industrial Applicability

[0089]

[0063] Best mode in Carrying out this invention : Structure of Battery Module or Battery Pack Housing can be Manufactured by Alumunium Extrusion Technology or Aluminum Low Pressure Casting but Prefer to Micro Port Exstrusion technology (MPE) due to lower cost, better surface finish quality, and can extrude thinner Profile, smaller liquid channel so that the weight of

[0090] Page 12 / 20 KLIB-DES-2024-002 PCT / IB2024 / 000002

[0091] Housing can be lighter than Casting Process Part. Liquid Channel can be square or round as Micro Channel tube or Precision multi port Exstrusion. The Micro Port Extrusion is a cutting-edge manufacturing process that involves the extrusion of small and intricate profiles with extreme precision.

[0092]

[0064] Manufacturing process Alternative : 1. Aluminum Exstrusion for plurality of battery cell Housing integrated with multi tube channel / multi port channel in one stroke; 2. 2. Table band sawing; 3. Leak test liquid channel and cell casing; 4. Machining at the end side of Housing (Front and Rear side) by Small End Mill (available 1-25 mm) to form Rib separator and Rib divider and surface finish Milling of Cover Plate surface and Lid surface to guarantee surface roughness and Flatness; 5. Welding cover plate both side (Front and Rear side) by Laser Welding; 6. Leak test for liquid channel; 7. Installation terminal Electrode by Lid welding, can done one by one or paralel multiple cell by single Lid ; 8. Leaktest Battery cells Casing.

[0093]

[0065] Size of Battery Module : Alternative 1, Follow ISO 21780 Road vehicles — New Standard of Supply voltage of 48 V. Total cells in Battery Module 13 Cells for Lithium Ferro Phosphate / LFP.

[0094]

[0066] Alternative 2, Follow Limitations of Section Width of Extrusion Procees. Aluminum large Exstrusion Press as Prior art can commonly extrude Maximum section Width of Aluminum Alloy 75-100 cm. For Litium ion Battery Pack for Passenger Car because of limitations in space battery module, because In a passenger electric vehicle, the battery pack is typically located along the floor pan of the vehicle or located under Body of vehicle, as Shown in Fig.l2A, Battery Pack Height (H) selected in range 9 - 11 cm.

[0095]

[0067] Furthermore For Commercial & public transport electric vehicles, for instance Battery Pack for Heavy Truck or Big Bus or Battery Energy Storage System (BESS) with regard to need of Bigger Energy and normally working voltage 800V, meanwhile space Available so that multiple battery packs can be located at the under body, rear sides or even the roof of the vehicle. Battery pack consisting of Plurality of Battery module can be extruded in one integrated unit Housing of Battery Pack as shown in Fig. 12B.

[0096] Page 13 / 20 KLIB-DES-2024-002 PCT / IB2024 / 000002

[0097]

[0068] Present Invention is aplicable to enhance Performance of Battery Pack Thermal Liquid Cooling System. Liquid cooling system consists of a compressor, condenser, expansion valve, plate heat exchanger, electronic water pump, PTC liquid heater , expansion tank, and electrical control. When the battery needs to be cooled for operation, the battery exchanges heat with the coolant through the cooling channel, and the heated coolant is sent into the heat exchanger by the electronic water pump. The refrigerant is introduced into one side of the heat exchanger and the coolant is introduced into the other side. The two exchange heat in the heat exchanger, so that the heat is taken away by the refrigerant. The cold coolant flows out of the heat exchanger and then flows into the battery. The system forms a cycle; when the battery is at low temperature and needs to be heated, the refrigeration circuit is closed and the PTC liquid heater is turned on. The coolant is heated and sent into the battery, and the battery is heated through the cooling plate. The battery thermal management controls the internal temperature of the battery by controlling the on and off of the refrigeration circuit and the PTC liquid heater.

[0098]

[0069] In current condition as better alternative, PTC liquid Heater can be replaced by Heat Pump because of more Energy Efficient and the Heat Pump can be Used for Heating and Cooling Liquid. Heat pumps use about half the power of a common car Heater.

[0099] Reference Signs List

[0100]

[0070] 100 BATTERY MODULE ASSEMBLY

[0101] 10 BATERY MODULE HOUSING

[0102] 11 Prismatic Battery Cell Casing 11-1 Battery Cell Casing 1 11-2 Battery Cell Casing 2 11-3 Battery Cell Casing 3 11-4 Battery Cell Casing 4 11-5 Battery Cell Casing 5

[0103] 12 Channel Divider Rib

[0104] 13 Channel Separator Rib

[0105] 14 Side Channel

[0106] Page 14 / 20 KLIB-DES-2024-002 PCT / IB2024 / 000002

[0107] 14-1 Side Channel 1

[0108] 14-2 Side Channel 2

[0109] 14-5 Side Channel 5

[0110] 15 Upper Channel

[0111] 15-1 Upper Channel 1

[0112] 15-2 Upper Channel 2

[0113] 15-5 Upper Channel 5

[0114] 16 Lower Channel

[0115] 16-1 Lower Channel 1

[0116] 16-2 Lower Channel 2

[0117] 16-5 Lower Channel 5

[0118] 17 Blind Hole M8

[0119] 18 Rear Side Casing

[0120] 19 Groove by Process Machining (Milling) by End Milling Cutter

[0121] 20 CELL CORE UNIT

[0122] 21 Electrode Terminal (+ or -)

[0123] 22 Front Lid

[0124] 23 Stacked Electrode / Jelly Roll

[0125] (Chatode, Anode, Separator)

[0126] 24 Rear Lid

[0127] 25 Lid of Plurality Battery cells integrated with Cover Plate

[0128] 30 FRONT COVER PLATE UNIT

[0129] 31 Front Cover Plate

[0130] 32 Tube of Liquid Outlet

[0131] 33 Lock Bolt M8

[0132] 40 REAR COVER PLATE UNIT

[0133] 41 Rear Cover Plate

[0134] 42 Tube of Liquid Inlet

[0135] 43 Lock Bolt M8

[0136] H = Height, L = Length, W = Width

[0137] 1000 BATTERY PACK ASSEMBLY

[0138] Page 15 / 20

Claims

AMENDED CLAIMS received by the International Bureau on March 2, 2026 (02.03.2026)Claims

1. (Amended)A battery module (100) or battery pack (1000) comprising:• a housing (10) formed as a monolithic single-piece structure by extrusion or casting, the housing (10) comprising a plurality of cell-receiving cavities or battery cell casings (11 ) and a network of internal liquid channels (14, 15, 16) integrally formed into the structure to provide thermal communication with peripheral surfaces of battery cells disposed within the cell-receiving cavities or battery cell casings (11 ) in an array configuration;• a plurality of rib separators (13) disposed within the housing (10), the rib separators (13) configured to isolate fluid passages to facilitate coolant flow in at least a first direction and a second direction different from the first direction;• a plurality of battery cell lids (22, 24) secured to the housing (10), wherein each battery cell lid (22, 24) comprises an integrated electrode terminal (21 ), a stacked electrode assembly (23), and a pressure relief mechanism; and• one or more cover plates (30, 40) secured to the housing (10) to enclose the internal liquid channels (14, 15, 16) and facilitate fluid communication to establish one or more serpentine coolant flow paths without external piping between adjacent cells; wherein the cover plates (30, 40) comprise at least one fluid inlet and at least one fluid outlet configured such that the flow path is adaptable for serial or parallel fluid distribution to manage temperature gradients across the plurality of battery cells; and wherein the one or more cover plates (30, 40) are either separate components from or integrally formed with the battery cell lids (22, 24) as a single integrated device.

2. (Amended)The battery module (100) or battery pack (1000) according to claim 1 , further comprising a plurality of rib dividers (12) disposed within the internal liquid channels to define multiple parallel passages for coolant flow.

3. (new)The battery module (100) or battery pack (1000) according to claim 1 , wherein the housing (10) is made of an aluminum alloy material to function as a structural chassis member of a vehicle.

4. (Amended)The battery module (100) or battery pack (1000) according to claim 1 , wherein the one or more cover plates (30, 40) comprise internal manifold structures configured to distribute coolant into multiple parallel sub-circuits within the monolithic housing to maintain a temperature gradient of less than 3°C across all battery cells.

5. (New)The battery module (100) or battery pack (1000) according to claim 1 , wherein the fluid inlet and outlet ports of the cover plates (30, 40) are configured for coupling to an external manifold system to facilitate parallel fluid distribution across multiple monolithic housings within an electric vehicle battery assembly or a battery energy storage system (BESS).

6. (Amended)The battery module (100) or battery pack (1000) according to claim 1 , wherein the internal liquid channels (14, 15, 16) are configured to provide direct thermal contact with at least four peripheral sides of each cell-receiving cavity or battery cell casing (11 ), while maintaining thermal isolation from the side of the integrated electrode terminals (21 ).

7. (New)The battery module (100) or battery pack (1000) according to claim 1 , wherein the network of internal liquid channels is further configured to provide thermal communication with a rear longitudinal surface (18) of each cell-receiving cavity or battery cell casing (11), thereby establishing five-sided thermal management for each battery cell to maximize heat transfer efficiency.

8. (Amended)The battery module (100) or battery pack (1000) according to claim 1 , wherein the one or more cover plates (30, 40) are secured to the housing (10) by a fastening means selected from the group consisting of: mechanical fasteners (33, 43) used in combination with a sealant gasket, epoxy bonding, and laser welding.

9. (Amended)The battery module (100) or battery pack (1000) according to claim 1 , wherein at least one of the cover plates (30, 40) is integrally formed with a plurality of the sealing means or battery cell lids (22, 24) to form a single integrated component (25).

10. (Amended)The battery module (100) or battery pack (1000) according to claim 1 or claim 2, wherein the internal liquid channels (14, 15, 16) comprise a plurality of microchannels integrally formed within the monolithic housing (10) via a multi-port extrusion (MPE) process to maximize the heat transfer surface area.

11. (Amended)The battery module (100) or battery pack (1000) according to claim 1 or claim 2, wherein the internal liquid channels (14, 15, 16) are defined by divider ribs (12) and separator ribs (13); characterized in that the divider ribs (12) have a longitudinal length shorter than a longitudinal length of the separator ribs (13) at the longitudinal ends of the housing (10) to facilitate an internal serpentine coolant flow path; and optionally further comprising machined grooves (19) to optimize fluid communication.

12. (New)The battery module (100) of claim 2, wherein a longitudinal length of each rib divider (12) is shorter than a longitudinal length of each rib separator (13) to define an internal fluid manifold configured for the redirection of coolant flow within the housing (10).

13. (New)The battery module (100) according to claim 1 , wherein the monolithic housing (10) is manufactured from a 6000-series aluminum alloy configured for high-pressure extrusion.

14. (New)The battery module (100) of claim 1 , wherein the network of internal liquid channels (14, 15, 16) is configured to provide a counter-flow arrangement between adjacent cell-receiving cavities (11 ) to minimize a temperature gradient across the array configuration.

15. (New)The battery module (100) of claim 8, wherein the micro-channels are configured with a hydraulic diameter optimized to balance heat transfer efficiency with a pressure drop across the monolithic housing (10).

16. (New)The battery module (100) according to claim 9, wherein the single integrated component (25) further comprises a laser-welded hermetic seal at the interface with the monolithic housing (10) to prevent coolant leakage.

17. (Replaced)An integrated sealing and cover plate assembly (25) for a battery module (100) or battery pack (1000), comprising:• a plurality of battery cell lids (22, 24), wherein each lid comprises an integrated electrode terminal (21 ), a stacked electrode assembly (23), an isolator, and a pressure relief mechanism; and• a cover plate (31 , 41 ) for enclosing internal liquid channels, wherein the cover plate (31 , 41 ) is integrally formed with the plurality of battery cell lids (22, 24) to define a single monolithic component (25).

18. (Replaced)In a battery module or battery pack housing (10) having a plurality of internal liquid channels (14, 15, 16), the improvement comprising:• the internal liquid channels (14, 15, 16) being integrally formed within the housing (10) as a monolithic structure via extrusion or casting;• wherein the channels are arranged such that a liquid coolant is in direct thermal communication with at least four peripheral surfaces of each cellreceiving cavity or cell casing (11 );• and wherein said internal liquid channels function as structural reinforcement members for the monolithic housing (10).

19. (Amended)An apparatus for storing electric energy, comprising:• housing means (10) for encasing a plurality of cell-receiving cavities (11 );• liquid channel means (14, 15, 16) integrally formed within the housing means(10) as a monolithic structure for managing the temperature of the apparatus;• divider rib means (12) disposed within the housing means (10) for defining a plurality of channels configured to direct liquid flow in a first direction;• separator rib means (13) disposed within the housing means (10) for defining a plurality of channels configured to direct liquid flow in a second direction;• cover plate means (30, 40) coupled to the housing means (10) for facilitating liquid flow between adjacent cell-receiving cavities (11 ) without external piping; and• sealing means (22, 24) for enclosing the cell-receiving cavities (11 ), coupled to the housing means (10) via a fixing means (33, 43).

20. (Amended)A process for manufacturing a battery module (100) or battery pack (1000) having integrated multi-channel liquid cooling, the process comprising the steps of:• extruding an aluminum profile to form a monolithic housing (10) comprising a plurality of cell-receiving cavities (11 ) and an integrated network of liquid channels (14, 15, 16);• cutting the extruded aluminum profile to a specified longitudinal length;• machining opposing longitudinal ends of the monolithic housing (10) to form a plurality of grooves (19) and to differentiate the lengths of the divider ribs (12) and separator ribs (13), thereby establishing an internal fluid manifold;• securing a first cover plate (30) and a second cover plate (40) to the opposing longitudinal ends of the housing (10) via laser welding or mechanical fastening to enclose the liquid channels;• performing a primary leak test on the network of liquid channels;• installing a plurality of battery cell lids (22, 24) onto the cell-receiving cavities (11 ), wherein each lid is integrated with an electrode terminal (21 ) and a stacked electrode assembly (23); and• performing a secondary leak test on the sealed cell-receiving cavities (11 ).

21. (Amended)A variant process for manufacturing a battery module (100) or battery pack (1000), the process comprising the steps of:• extruding an aluminum profile to form a monolithic housing (10) comprising a plurality of cell-receiving cavities (11 ) and an integrated network of liquid channels (14, 15, 16);• cutting the extruded aluminum profile to a specified longitudinal length;• machining opposing longitudinal ends of the monolithic housing (10) to define internal liquid channels (14, 15, 16), divider ribs (12), and separator ribs (13);• performing a primary leak test on the internal liquid channels;• securing an integrated sealing and cover plate assembly (25) to at least one of the opposing longitudinal ends of the housing (10) in a single-step attachment operation, thereby simultaneously enclosing the liquid channels and sealing the cell-receiving cavities (11 ); and• performing a secondary leak test on the cell-receiving cavities (11 ).

22. (Amended)A variant process for manufacturing a battery module (100) or battery pack (1000), the process comprising the steps of:• casting an aluminum housing (10) to integrally form a plurality of cell-receiving cavities (11 ), internal liquid channels (14, 15, 16), and at least one cover plate (30, 40) as a single monolithic cast unit;• performing a primary leak test on the integrated liquid channels of said monolithic cast unit;• securing an integrated sealing member assembly (25) into the aluminum housing (10) in a single-step attachment operation, thereby simultaneously sealing the plurality of cell-receiving cavities (11 ) containing integrated electrode terminals (21 ) and stacked electrode assemblies (23); and• performing a secondary leak test on the sealed cell-receiving cavities (11 ).

23. (Replaced)A method for managing the temperature of a plurality of battery cells within a battery module (100) or battery pack (1000), the method comprising:• providing a battery module (100) or battery pack (1000) comprising an integrated monolithic housing (10) as claimed in claim 1 ;• circulating a liquid coolant through a network of internal liquid channels (14, 15, 16) integrally formed within the monolithic housing (10) to absorb or provide thermal energy;• directing the coolant through a serpentine flow path defined by a plurality of rib dividers (12) and rib separators (13) to facilitate thermal exchange with at least four peripheral surfaces of each cell-receiving cavity (11); and• facilitating intracavity and intercavity coolant flow using cover plates (30, 40) at opposing longitudinal ends of the housing (10) to establish a continuous fluid circuit without external piping between adjacent cells.

24. (Replaced)Use of a battery module (100) or battery pack (1000) comprising a monolithic housing (10) with integrally extruded internal liquid channels (14, 15, 16) for managing the temperature of a plurality of electric energy storage cells, the use comprising:• circulating a liquid coolant through the integrally extruded internal liquid channels (14, 15, 16) to provide thermal communication with substantially all peripheral surfaces of the cell-receiving cavities (11 ) except for a side through which the electrode terminals (21 ) extend;• directing coolant flow through a defined path using separator ribs (13) and divider ribs (12) integrated within the monolithic housing (10); and• facilitating intracavity and intercavity coolant flow using cover plates (30, 40) at opposing longitudinal ends of the monolithic housing (10) to establish a continuous fluid circuit without external piping between adjacent cell-receiving cavities (11 ).

25. (New)Use of a battery module (100) or battery pack (1000) housing (10), as claimed in claim 1 , for managing the temperature of a plurality of battery cells, the use comprising:• circulating a liquid coolant through the network of internal liquid channels (14, 15, 16) to absorb or provide thermal energy;• directing the liquid coolant through a serpentine flow path defined by the rib dividers (12) and the rib separators (13) to facilitate thermal communication with at least four peripheral surfaces of each cell-receiving cavity (11 ); and• facilitating intracavity and intercavity coolant flow using the cover plates (30, 40) at opposing longitudinal ends of the housing (10) to establish a continuous fluid circuit without external piping between adjacent cell-receiving cavities (11 ).

26. (New)The battery module (100) or battery pack (1000) according to claim 1 , wherein the monolithic housing (10) and the integrated network of internal liquid channels (14, 15, 16) are configured to function as a thermal barrier and structural heat sink; characterized in that the high thermal conductivity of the monolithic housing (10) is configured to dissipate localized caloric energy from a failing cell to the liquid coolant, thereby mitigating thermal runaway propagation between adjacent cellreceiving cavities (11 ).

27. (New)The battery module (100) or battery pack (1000) according to claim 1 , wherein the monolithic housing (10) is composed of a material having a thermal conductivity of at least 180 W / m K to maintain a temperature gradient of less than 2°C across the plurality of cell-receiving cavities (11 ) during a standard discharge cycle.

28. (New)The battery module (100) or battery pack (1000) according to claim 1 , wherein a plurality of monolithic housings (10) are configured to be mechanically and thermally coupled in a modular array; characterized in that the internal liquid channels (14, 15, 16) of adjacent housings (10) are in fluid communication via a shared manifold system, enabling the entire modular array to be managed by a single thermal control unit without individual external hoses between adjacent modules.

29. (New)The battery module (100) or battery pack (1000) according to claim 1 , wherein the monolithic aluminum housing (10) is configured to function as a Faraday cage; providing electromagnetic interference (EMI) shielding to protect the internal battery cells and integrated electrode assemblies (23) from external electrical noise and to contain electromagnetic emissions generated during high-voltage operation.;

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