Battery Module Adhesive Composition for Uniform Cell Cooling

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Solution Overview

Problem

In high-voltage, large-format battery modules, uneven thermal gradients across battery cells lead to uneven cooling, causing some cells to degrade faster and complicating temperature estimation, especially when using temperature sensors, which add cost and complexity.

Innovation Solution

A battery module design using a cooling surface with varying thermal conductivity adhesive to secure battery cells, compensating for cooling capacity differences by adjusting the ratio of adhesive components based on cooling profiles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If battery cells are arranged closely to provide high energy density, then energy density is improved, but thermal gradient control becomes difficult

Engineering Contradiction:

Improveenergy densityVSAvoidthermal gradient control

Core Design Contradiction:

Quantity of substanceVSTemperature

Solution Approach 1:

The adhesive's thermal conductivity is varied locally across different regions of the cooling surface. Specifically, the adhesive has a first thermal conductivity in a first region and a second thermal conductivity in a second region, allowing each region to compensate for the inherent non-uniform cooling capacity of the cooling surface, thereby achieving uniform thermal gradients across all battery cells while maintaining high energy density

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The thermal conductivity parameter of the adhesive is changed across different regions to address the thermal gradient issue. By adjusting the thermal conductivity of the adhesive in different regions (first thermal conductivity in first region, second thermal conductivity in second region), the system compensates for the non-uniform cooling capacity and achieves uniform cooling across all battery cells

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If cooling capacity varies across the cooling surface, then manufacturing simplicity is improved, but uniform cooling of battery cells deteriorates

Engineering Contradiction:

Improvecooling surface manufacturingVSAvoiduniform cooling

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The adhesive is designed with spatially varying thermal conductivity properties to compensate for the non-uniform cooling capacity of the cooling surface. The adhesive has a first thermal conductivity in a first region and a second thermal conductivity in a second region, allowing each region to be optimized for its specific cooling requirements while maintaining overall uniformity

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The adhesive is formulated as a composite material with different thermal conductivity regions. This composite adhesive structure allows different portions of the adhesive to have different thermal conductivities, enabling compensation for the cooling surface's non-uniform cooling capacity and achieving uniform cooling across all battery cells

Inventive Principle:

Principle #40Composite materials

3Measurement precision

If temperature sensors are added to all battery cells, then temperature measurement accuracy is improved, but device complexity and cost increase

Engineering Contradiction:

Improvetemperature measurementVSAvoidsensor network complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The adhesive itself serves as a thermal management component that actively compensates for cooling non-uniformity. By embedding the thermal conductivity variation directly into the adhesive material, the system achieves uniform cooling without requiring additional sensors or complex control systems on each battery cell

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The adhesive acts as an intermediary thermal management component between the cooling surface and the battery cells. By varying the adhesive's thermal conductivity in different regions, it mediates the heat transfer process to compensate for the cooling surface's non-uniformity, eliminating the need for individual temperature sensors on each cell

Inventive Principle:

Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Ensures uniform cooling of all battery cells, preventing uneven degradation and simplifying temperature estimation without the need for extensive sensor networks.

Implementation Method 1

an adhesive including a first component having a first thermal conductivity and a second component having a second thermal conductivity

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS12401076B2Temperature gradient control with thermal interface material variation

Publication Date: 2025.08.26 RIVIAN HOLDINGS LLC

AI summary

A battery module and a method of assembling the battery module are provided. The battery module includes a cooling surface having a first area and a second area with different cooling capacities, an adhesive including a first component having a first thermal conductivity and a second component having a second thermal conductivity, and a first battery and a second battery. The first battery is secured to the first area by a first portion of the adhesive and the second battery is secured to the second area by a second portion the adhesive. The first portion of the adhesive has a first ratio of the first component to the second component and the second portion of the adhesive has a second ratio of the first component to the second component. The first and second ratios are different and compensate for the different cooling capacities of the first and second areas.