Battery Thermal Management via Integrated Cooling Modules

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Solution Overview

Problem

Traditional airflow systems for battery assemblies are inefficient in thermal conduction and occupy significant space, posing challenges in minimizing size and weight while maintaining performance and extending battery life.

Innovation Solution

An integrated thermal management system utilizing thermally conductive bases and cooling modules with thermally conductive members that directly abut each other and the battery cells, eliminating the need for thermal interface materials and optimizing heat transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If traditional airflow systems are used to dissipate heat from battery cells, then heat dissipation function is provided, but the system occupies large space and has insufficient thermal conduction from battery cell interiors

Engineering Contradiction:

Improveheat dissipation effectivenessVSAvoidspace occupied by cooling system

Core Design Contradiction:

TemperatureVSVolume of stationary object

Solution Approach 1:

The cooling modules are integrated directly with the battery cell structures, merging the cooling function into the battery assembly itself. The first cooling module is disposed within the first battery cell and the second cooling module is disposed within the second battery cell, eliminating the need for separate external cooling systems and reducing overall space occupation.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Thermally conductive members are introduced as intermediary elements between the battery cell interiors and the cooling modules. These members facilitate efficient thermal conduction from the battery cell interiors to the cooling modules, addressing the insufficient thermal conduction problem of traditional airflow systems.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Temperature

If traditional airflow systems are used for thermal management, then heat dissipation is achieved, but the system weight increases

Engineering Contradiction:

Improveheat dissipation effectivenessVSAvoidweight of battery assembly

Core Design Contradiction:

TemperatureVSWeight of stationary object

Solution Approach 1:

The cooling modules are integrated directly with the battery cell structures, merging the cooling function into the battery assembly itself. This integration eliminates the need for separate external cooling systems and their associated heavy components, thereby reducing overall system weight while maintaining heat dissipation effectiveness.

Inventive Principle:

Principle #5Merging (Combining)

3Temperature

If cooling modules with multiple thermally conductive members are integrated directly with battery cells, then thermal conduction is enhanced, but manufacturing complexity increases

Engineering Contradiction:

Improvethermal conduction efficiencyVSAvoidmanufacturing complexity

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The thermal management system is segmented into modular cooling modules, each associated with specific battery cells. Each cooling module contains multiple thermally conductive members that can be independently manufactured and then assembled, simplifying the overall manufacturing process while maintaining high thermal conduction efficiency.

Inventive Principle:

Principle #1Segmentation

4Volume of stationary object

If cooling modules are disposed within battery cells, then space is minimized, but assembly complexity increases

Engineering Contradiction:

Improvespace occupationVSAvoidassembly complexity

Core Design Contradiction:

Volume of stationary objectVSDevice complexity

Solution Approach 1:

The battery assembly is divided into multiple modular units, each containing battery cells with integrated cooling modules. This segmentation allows for standardized assembly procedures where pre-assembled cooling modules are installed with battery cells, reducing overall assembly complexity despite the integrated design.

Inventive Principle:

Principle #1Segmentation

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

This solution enhances heat transfer coefficients and reduces manufacturing complexity, minimizing space requirements while ensuring effective thermal conduction and prolonged battery life.

Implementation Method 1

cooling modules are configured to be directly abutting at least one thermally conductive base... at least one battery cell disposed adjacent and in heat transfer relationship with the cooling modules

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS9490508B2Battery assembly having a thermal management system

Publication Date: 2016.11.08 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A battery assembly includes a plurality of battery cells disposed adjacent and in heat transfer relationship with a plurality of cooling modules. The cooling modules are directly affixed to or cause to abut at least one of a first thermally conductive base and a second thermally conductive base forming a thermal transfer path from the battery cells through the cooling modules to the at least one thermally conductive base.