Battery Module Frame With Integrated Cooling Channels

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Solution Overview

Problem

Existing battery modules face challenges in efficient heat dissipation, complex assembly processes, and high manufacturing costs due to the use of solid structures with additional cooling plates or extruded profiles, leading to increased parts and assembly steps, which complicates thermal management and mechanical integration.

Innovation Solution

A battery module design featuring a frame with integrated cooling channels formed by roll-bonding a first metal sheet with a second metal sheet, where the sheets are bent and inflated to create a U-shaped structure that accommodates battery cells, allowing for efficient heat transfer without additional assembly steps.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If solid structures with additional cooling plates or extruded profiles are used, then cooling channels can be provided, but the number of parts and assembly steps increases

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoidnumber of parts and assembly steps

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent combines the frame structure and cooling channels into a single integrated component. The frame includes internally formed cooling channels that are manufactured as part of the frame itself, eliminating the need for separate cooling plates or extruded profiles. This merging of functions reduces the total number of parts and assembly steps while maintaining effective heat dissipation from the battery cells.

Inventive Principle:

Principle #5Merging (Combining)

2Temperature

If additional cooling plates are used, then thermal management is improved, but manufacturing costs increase

Engineering Contradiction:

Improvethermal management efficiencyVSAvoidmanufacturing cost

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The cooling channels are integrated directly into the frame structure during frame manufacturing. This eliminates the need for separate cooling plates and reduces the total number of manufacturing operations. The frame is produced with internally formed cooling channels as a single component, reducing manufacturing complexity and cost while maintaining effective thermal management.

Inventive Principle:

Principle #5Merging (Combining)

3Strength

If extruded profiles are used for frame and cooling channels, then structural integrity is maintained, but assembly complexity increases

Engineering Contradiction:

Improvestructural integrityVSAvoidassembly complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The frame is manufactured as a single integrated component with cooling channels formed internally. This eliminates the need to assemble separate extruded profiles and cooling channel components. The frame maintains its structural integrity for mechanical support while the integrated cooling channels are built-in during frame production, eliminating assembly steps.

Inventive Principle:

Principle #5Merging (Combining)

4Temperature

If separate cooling channels are added to the frame, then heat dissipation is improved, but the number of manufacturing steps increases

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoidmanufacturing efficiency

Core Design Contradiction:

TemperatureVSProductivity

Solution Approach 1:

The cooling channels are formed as integral parts of the frame during the frame manufacturing process itself. The channels are created in advance as part of the frame structure through internally formed cavities, rather than being added as separate components in subsequent assembly steps. This preliminary integration of cooling functionality into the frame production improves manufacturing efficiency.

Inventive Principle:

Principle #10Preliminary action

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

The design reduces manufacturing costs and complexity by integrating cooling channels directly into the frame, enhancing thermal management and mechanical strength while simplifying assembly, thus improving the battery module's performance and durability.

Implementation Method 1

a first metal sheet (32) on an inner side of the plate and a second metal sheet (34) on an outer side of the plate roll-bonded to each other

Methodology Applied

Scientific EffectRoll-bonding:

Implementation Method 2

the plate further includes at least one cooling channel formed between bonding areas of the first metal sheet and the second metal sheet

Methodology Applied

Scientific EffectInflation:

Data Source

PatentUS20250329818A1Battery module and method of manufacturing the same

Publication Date: 2025.10.23 SAMSUNG SDI CO LTD

AI summary

A battery module includes a plurality of battery cells, and a frame including a bottom member and a plurality of side walls, the bottom member and the plurality of side walls forming an interior accommodation space configured to accommodate the plurality of battery cells, wherein at least two side walls opposite from each other among the plurality of side walls are bent and extend from the bottom member, wherein the at least two side walls and the bottom member are formed by a plate including a first metal sheet on an inner side of the plate and a second metal sheet on an outer side of the plate roll-bonded to each other, and wherein the plate further includes at least one cooling channel formed between bonding areas of the first metal sheet and the second metal sheet.