Formed-In-Place Battery Module Thermal Paths for Lightweight Cooling

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Solution Overview

Problem

Conventional battery modules with resin-based housings lack effective thermal management, leading to thermal excursions that can shut down charging or discharging, and adding aluminum thermal-management components increases weight and reduces gravimetric energy density.

Innovation Solution

The integration of a formed-in-place thermal-management component within the housing of the battery module, using a flowable thermally conductive material that solidifies to conduct heat from the battery core to the exterior of the housing, thereby enhancing thermal management without increasing weight.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If an aluminum thermal-management component is added to the battery module, then thermal management capability is improved, but weight increases and gravimetric energy density decreases

Engineering Contradiction:

Improvethermal management capabilityVSAvoidmodule weight

Core Design Contradiction:

TemperatureVSWeight of moving object

Solution Approach 1:

The patent merges the thermal management function with the existing housing structure by integrating a thermal management component into the bottom wall of the housing. This integration allows the housing to simultaneously serve as structural support and thermal conduction pathway, achieving thermal management without adding separate heavy aluminum components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent employs a composite structure where the housing wall combines dielectric material with an integrated thermal management component. The thermal management component is formed within the housing structure itself, creating a composite assembly that provides both structural integrity and thermal conduction capabilities while maintaining lightweight characteristics.

Inventive Principle:

Principle #40Composite materials

2Weight of moving object

If no thermal management component is included in the battery module, then weight is reduced and gravimetric energy density is improved, but thermal excursions occur and operational reliability deteriorates

Engineering Contradiction:

Improvemodule weightVSAvoidoperational reliability

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The patent combines thermal management functionality with the housing structure, allowing the same component to provide both mechanical support and thermal conduction. This integration ensures reliable thermal management is present without requiring separate heavy aluminum heat sinks, thus maintaining both lightweight design and operational reliability.

Inventive Principle:

Principle #5Merging (Combining)

3Strength

If a rigid housing with low thermal conductivity is used, then structural integrity is maintained, but heat conduction from the battery core is insufficient

Engineering Contradiction:

Improvehousing structural integrityVSAvoidheat conduction capability

Core Design Contradiction:

StrengthVSTemperature

Solution Approach 1:

The patent integrates a thermal management component directly into the housing wall structure, creating a hybrid assembly where the dielectric housing provides structural integrity while the integrated thermal management component provides heat conduction pathways. This merging allows the housing to simultaneously maintain structural strength and improve thermal transport from the battery core.

Inventive Principle:

Principle #5Merging (Combining)

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 provides effective thermal management for battery modules, preventing thermal excursions and maintaining operational integrity while maintaining a lightweight design and high gravimetric energy density.

Implementation Method 1

a formed-in-place thermal-management component extending through the wall of the housing so that, during use of the battery module, the formed-in-place thermal management component can conduct heat from the battery core to the exterior side of the wall

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

causing the flowable material to solidify so as to create a formed-in-place thermal-management component

Methodology Applied

Scientific EffectPhase change (solidification): Phase Change

Data Source

PatentUS20250149672A1Battery Modules Having Formed-In-Place Thermal-Management Components, and Methods of Making Such Battery Modules

Publication Date: 2025.05.08 SES (SHANGHAI) CO LTD

AI summary

The present application relates to battery modules and methods of making battery modules. Battery modules having formed-in-place thermal-management components, made from flowable material, that during use of the battery modules functions to conduct heat from battery cores inside the battery modules to heat sinks located outside the battery modules. In some embodiments, the battery module has a housing made of a relatively lightweight material that has a relatively low thermal conductivity, and the formed-in-place thermal-management component is made of a material that has a thermal conductivity higher than the thermal conductivity of the housing material. Methods of making such formed-in-place thermal-management component are also disclosed.