Laser-Welded Inflatable Cooling Plate for Battery Thermal Management

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Solution Overview

Problem

Conventional cooling systems for vehicle batteries, such as those in hybrid, electric, and fuel cell vehicles, face challenges due to high manufacturing costs and weight addition, as well as reduced mechanical properties resulting from high-temperature forming processes, which impact their performance and reliability.

Innovation Solution

A method of forming a cooling plate through laser welding of substrates to create an inflatable track, which is then inflated to form a cooling channel, providing a fluid-tight seal and increased tensile strength without the need for high-temperature brazing, allowing for reduced costs and weight while maintaining effective coolant flow.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If conventional high-temperature forming processes are used to create cooling plates, then cooling channels can be formed, but the mechanical properties of the cooling plates are reduced

Engineering Contradiction:

Improveforming temperatureVSAvoidmechanical properties

Core Design Contradiction:

TemperatureVSStrength

Solution Approach 1:

The patent replaces conventional high-temperature mechanical forming processes with a low-temperature inflatable mold system. The cooling channels are formed by inflating a mold within the substrate at temperatures below the melting point of the substrate material, thereby avoiding thermal degradation while achieving the desired channel geometry.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the temperature parameter from conventional high-temperature forming to low-temperature inflation. By controlling the inflation temperature to remain below the substrate's melting point, the process maintains the substrate's mechanical properties while still forming the cooling channels effectively.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If conventional cooling systems are implemented in battery packs, then temperature regulation is achieved, but manufacturing costs and weight increase significantly

Engineering Contradiction:

Improvetemperature regulationVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent merges the cooling plate structure directly with the battery pack housing or structural components. By integrating the cooling channels into the existing substrate rather than adding separate cooling components, the design achieves effective temperature regulation while reducing manufacturing costs and avoiding significant weight increase.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The substrate serves multiple functions: it provides structural support for the battery pack and simultaneously contains the cooling channels for temperature regulation. This multi-functionality eliminates the need for separate cooling system components, thereby reducing manufacturing costs and weight while maintaining reliable thermal management.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If conventional cooling systems are added to battery packs, then cooling capability is provided, but the weight of the battery pack increases significantly

Engineering Contradiction:

Improvecooling capabilityVSAvoidbattery pack weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The cooling channels are integrated directly into the battery pack's structural substrate, combining the structural and thermal management functions into a single component. This integration eliminates the need for separate cooling system weight, achieving effective cooling while minimizing impact on battery pack weight.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent uses thin substrate materials with embedded cooling channels rather than thick, heavy conventional cooling plates. The inflatable mold process enables the formation of cooling channels in thin-walled structures, reducing the overall weight of the cooling system while maintaining adequate cooling capability.

Inventive Principle:

Principle #30Flexible shells and thin films

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 laser-welded and inflated cooling plate offers improved mechanical properties, reduced manufacturing costs, and weight reduction, while maintaining effective coolant flow and temperature regulation for battery systems, enhancing the performance and reliability of battery cooling systems.

Implementation Method 1

laser welding a plurality of weld lines to physically connect a first substrate and a second substrate wherein the plurality of weld lines forms an inflatable track therebetween

Methodology Applied

Scientific EffectLaser welding: Laser Beam Welding

Implementation Method 2

The inflatable track can then be inflated with an inflation fluid to form a cooling channel in the cooling plate

Methodology Applied

Scientific EffectPressure inflation: Pressure Increase

Data Source

PatentUS11549626B2Method of forming a cooling plate

Publication Date: 2023.01.10 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

In an embodiment, a method of forming a cooling plate, comprises laser welding a plurality of weld lines to physically connect a first substrate and a second substrate wherein the plurality of weld lines forms an inflatable track; and inflating the inflatable track with an inflation fluid to form a cooling channel in the cooling plate. In another embodiment, the cooling plate can comprise a first substrate and a second substrate and a plurality of weld lines can form a fluid tight seal for a cooling channel located therebetween.