Pouch Cell Module Bracket Layout for Compact Battery Cooling

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing battery cooling systems for electric vehicles fail to efficiently remove heat from stacked pouch cells, leading to compromised power efficiency and safety concerns due to overheating, and are either costly or prone to coolant leakage.

Innovation Solution

A system comprising pouch cell modules with brackets made of thermally conductive materials, insulation pads, and compression bands that hold and protect individual cells, allowing for efficient heat conduction and modular assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If pouch cells are stacked close together to optimize space usage, then packaging efficiency is improved, but heat removal becomes difficult and overheating occurs

Engineering Contradiction:

Improvespace utilizationVSAvoidheat removal efficiency

Core Design Contradiction:

Volume of moving objectVSTemperature

Solution Approach 1:

The battery pack is divided into multiple pouch cell modules, each with its own cooling brackets and insulation pads. This segmentation allows heat to be managed at the module level rather than requiring a single complex cooling system for the entire pack, improving heat removal efficiency while maintaining compact arrangement.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Thermally conductive brackets are positioned in direct contact with battery cells at specific locations where heat generation is highest, while insulation pads are placed between adjacent cells to prevent heat accumulation. This localized thermal management approach optimizes heat removal from critical areas without requiring cooling of the entire structure.

Inventive Principle:

Principle #3Local quality

2Temperature

If cooling gel is applied at the bottom enclosure to remove heat, then cooling is achieved, but large temperature difference occurs across the cell perpendicular to the cooling surface

Engineering Contradiction:

Improvecooling effectivenessVSAvoidtemperature uniformity

Core Design Contradiction:

TemperatureVSManufacturing precision

Solution Approach 1:

Instead of applying cooling only at the bottom surface (one-dimensional cooling), the invention introduces cooling brackets that contact the sides of the battery cells, creating multi-dimensional heat dissipation pathways. This allows heat to be removed from multiple surfaces simultaneously, reducing temperature gradients across the cell and improving temperature uniformity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Strength

If plastic frame with cooling foam is used to hold cells together, then structural support is provided, but cost increases and liquid leakage risk occurs

Engineering Contradiction:

Improvestructural supportVSAvoidcost and reliability

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The invention extracts the cooling function from the structural frame component, using separate metal brackets for both mechanical support and thermal management. This eliminates the need for integrated plastic frames with cooling foam, reducing manufacturing complexity and eliminating liquid leakage risks while maintaining structural integrity.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Metal brackets serve as intermediary components that simultaneously provide structural support and thermal conduction. These brackets act as mediators between the battery cells and the cooling system, eliminating the need for plastic frames while maintaining both mechanical strength and cooling effectiveness.

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

The system effectively conducts heat away from each cell, provides structural protection, prevents coolant leakage, and allows for flexible module configurations, enhancing cooling performance and safety while maintaining cost-effectiveness.

Implementation Method 1

brackets made of thermally conductive materials, insulation pads, and compression bands that hold and protect individual cells, allowing for efficient heat conduction

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

an insulation pad positioned between the pair of battery cells

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS12573683B2Battery module including pouch cell module with cells separated by insulator and tabs extending across insulator

Publication Date: 2026.03.10 KARMA AUTOMOTIVE LLC

AI summary

A battery module made from a plurality of side-by-side pouch cell modules, wherein each pouch cell module is formed with a pair of cells on either side of an insulation pad with the cells in turn positioned between first and second metal brackets such that each cell contacts an insulation pad on one side and a metal bracket on the other. Also included is a pair of pressure plates at the ends of the stack of side-by-side pouch cells and a compression band wrapping around the plurality of side-by-side pouch cells and the pressure plates. A busbar electrically connects the plurality of side-by-side pouch cells together.