Extruded Aluminum Battery Module Thermal Management

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Solution Overview

Problem

Existing battery cell packaging and thermal management systems face challenges in maintaining optimal operating temperatures, preventing short-circuits, and protecting against damage, particularly due to the lack of effective thermal conductivity and structural support for battery cells.

Innovation Solution

The use of extruded aluminum or aluminum alloy profiles with integrated thermal transfer fins and channels, along with a shoulder structure to prevent direct contact between battery terminals and the profile, allows for efficient thermal energy transfer while providing a protective and supportive housing for the battery cells, using an electrically insulating thermal compound for enhanced heat conduction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If battery cells are cooled directly from the battery terminals, then thermal management efficiency is improved, but short-circuit risk increases

Engineering Contradiction:

Improvethermal management efficiencyVSAvoidshort-circuit risk

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The patent introduces an electrically insulating thermal compound as an intermediary substance between the battery terminal and cooling structure. This compound has high thermal conductivity to transfer heat effectively while being electrically insulating to prevent short-circuits, thus resolving the contradiction between thermal management efficiency and safety.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces direct electrical contact (mechanical/electrical connection) with thermal contact through an insulating compound. Instead of allowing electrical current to flow through the cooling structure, the system uses thermal conduction through an electrically insulating material, substituting the electrical connection mechanism with a thermal one.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Device complexity

If extruded aluminum profiles with integrated channels are used, then device complexity is reduced, but manufacturing precision requirements increase

Engineering Contradiction:

Improvenumber of componentsVSAvoidextrusion precision

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent merges multiple separate components (housing structure, thermal management channels, and support elements) into a single integrated extruded aluminum profile. This consolidation reduces the total number of parts and assembly steps while requiring high precision in the extrusion process to ensure proper channel formation and thermal contact surfaces.

Inventive Principle:

Principle #5Merging (Combining)

3Temperature

If thermal transfer fins are positioned close to battery cells, then heat transfer efficiency is improved, but risk of damage to battery cells increases

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidrisk of damage

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The patent uses electrically insulating thermal compound as a mediator between the thermal transfer fins and battery cell surfaces. This compound layer maintains intimate thermal contact for efficient heat transfer while providing a protective cushion that prevents mechanical damage to the battery cells from direct contact with the fins or profile structure.

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

This solution enables scalable and efficient thermal management, minimizing internal couplings and components, ensuring reliable heat transfer and protection against damage, allowing for safe and effective temperature regulation and prevention of short-circuits in battery modules.

Implementation Method 1

thermal energy is conducted through said aluminum or aluminum alloy profile from/to the battery cells to/from said thermal transfer fluid

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

a plurality of thermal transfer fins arranged at a space from each other... thermal energy is conducted through said aluminum or aluminum alloy profile

Methodology Applied

Scientific EffectThermal radiation: Thermal Radiation

Data Source

PatentEP2997622B1System for packaging and thermal management of battery cells

Publication Date: 2018.07.04 VALMET AUTOMOTIVE OY

Figure 1~4
Figure 5~6

AI summary

The present invention relates to a system for packaging and thermal management of battery cells in a battery module. The battery module comprises at least one extruded aluminum or aluminum alloy profile (40) provided with a plurality of thermal transfer fins (42) arranged at a space from each other. A plurality of battery cells (1) is mounted in said at least one profile (40) in thermal contact with the thermal transfer fins (42). Thermal transfer medium is arranged in thermal contact with said at least one profile (40) so that thermal energy is conducted through said aluminum or aluminum alloy profile (40) from/to the battery cells (1) to/from said thermal transfer fluid.