Preformed Battery Module Insert With Coolant Channels

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Solution Overview

Problem

Existing battery cell cooling systems require labor-intensive manufacturing processes and materials, such as epoxy fillers, to create fixed thermal pathways, which are inefficient and time-consuming.

Innovation Solution

A preformed insert made of a potting material with defined cavities and coolant channels is used to conduct thermal energy away from battery cells, eliminating the need for pouring and solidifying materials, and allowing coolant to be cycled for improved thermal distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If epoxy filler or solidifying material is poured into the battery module to create fixed thermal pathways, then thermal conduction is achieved, but manufacturing complexity and time increase due to multiple steps including pouring, sealing, proofing, and heating

Engineering Contradiction:

Improvethermal conductionVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The cooling channels are pre-formed in the cell holder before the battery cells are installed. This preliminary action eliminates the need for pouring and solidifying filler material after cell installation, reducing manufacturing steps while maintaining effective thermal pathways. The channels are created in advance using molding or machining techniques on the cell holder structure itself.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention extracts the filler material function by integrating the cooling channels directly into the cell holder structure. Instead of using separate filler material to create thermal pathways, the cell holder itself is designed with built-in channels that perform the same thermal management function, eliminating the need for additional materials and processing steps.

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If epoxy filler or solidifying material is used to create fixed thermal pathways, then thermal conduction is achieved, but manufacturing time increases due to labor-intensive processes

Engineering Contradiction:

Improvethermal conductionVSAvoidmanufacturing speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention replaces the mechanical process of pouring and solidifying filler material with a pre-formed structural design. The cooling channels are created through molding or machining operations performed before assembly, substituting the time-consuming post-assembly filler process with efficient pre-manufacturing techniques.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If fixed thermal pathways with immovable filler are used, then thermal conduction is provided, but thermal distribution efficiency is reduced compared to cycling coolant

Engineering Contradiction:

Improvethermal conductionVSAvoidthermal distribution efficiency

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The invention transitions from static thermal pathways filled with immovable material to dynamic cooling channels that circulate coolant. The coolant continuously flows through the channels, actively carrying heat away from the battery cells, which improves thermal distribution efficiency compared to passive conduction through fixed filler material.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The invention uses hydraulic cooling by circulating liquid coolant through the cooling channels. This fluid-based thermal management system efficiently transports heat through the movement of coolant, providing superior thermal distribution compared to solid filler materials that rely solely on thermal conduction.

Inventive Principle:

Principle #29Pneumatics and hydraulics

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 preformed insert provides efficient thermal management by cycling coolant through channels, enhancing thermal distribution and reducing manufacturing complexity and time.

Implementation Method 1

a preformed insert made of a potting material with defined cavities and coolant channels is used to conduct thermal energy away from battery cells

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

allowing coolant to be cycled for improved thermal distribution

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

The preformed insert provides efficient thermal management by cycling coolant through channels

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 4

cycling coolant through the cooling channels to conduct thermal energy away from the battery cells

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS20250210752A1Preformed insert for battery module

Publication Date: 2025.06.26 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A battery module having a preformed insert. The battery module may include a plurality of battery cells configured for storing and supplying electrical power and a cell holder configured for supporting the battery cells. The preformed insert may be disposed relative to the cell holder and the battery cells and formed to include a potting material shaped to define a plurality of coolant channels around the battery cells.