Roll-Bonded Battery Module Frame With Inflated Cooling Channels

Solution Overview

Problem

Existing battery modules require complex assembly processes due to the incorporation of additional cooling plates or extruded profiles, leading to increased manufacturing effort and costs, while offering limited cooling performance and structural integrity.

Innovation Solution

A battery module design featuring a frame formed by roll-bonded metal sheets with integrated cooling channels, where two opposite side walls are bent and extended from a bottom member, allowing for efficient heat dissipation without additional assembly steps.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If additional cooling plates or extruded profiles are incorporated into battery modules, then cooling performance is improved, but device complexity and manufacturing effort increase

Engineering Contradiction:

Improvecooling performanceVSAvoidassembly process complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The frame and cooling channels are merged into a single integrated structure. The frame includes cooling channels formed by inflating an inflatable element within the frame structure, eliminating the need for separate cooling plates or extruded profiles. This integration reduces the number of components and assembly steps while maintaining effective cooling performance.

Inventive Principle:

Principle #5Merging (Combining)

2Temperature

If additional cooling plates or extruded profiles are incorporated into battery modules, then cooling performance is improved, but manufacturing costs increase

Engineering Contradiction:

Improvecooling performanceVSAvoidmanufacturing cost

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The frame and cooling channels are merged into a single integrated structure. The frame includes cooling channels formed by inflating an inflatable element within the frame structure, eliminating the need for separate cooling plates or extruded profiles. This integration reduces the number of components and assembly steps while maintaining effective cooling performance.

Inventive Principle:

Principle #5Merging (Combining)

3Strength

If battery modules are housed in a complete battery system with housing, then structural protection is improved, but ease of repair deteriorates

Engineering Contradiction:

Improvestructural protectionVSAvoidcomponent replacement difficulty

Core Design Contradiction:

StrengthVSEase of repair

Solution Approach 1:

The battery system is segmented into modular battery modules that can be independently removed and replaced. Each battery module is designed as a self-contained unit with its own frame and cooling channels, allowing defective modules to be replaced without disassembling the entire battery system or removing the housing.

Inventive Principle:

Principle #1Segmentation

4Strength

If battery systems are fixed with complete housing and mounting structure, then structural integrity is improved, but adaptability deteriorates

Engineering Contradiction:

Improvestructural integrityVSAvoidinstallation flexibility

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The battery system is segmented into modular battery modules that can be independently removed and replaced. Each battery module is designed as a self-contained unit with its own frame and cooling channels, allowing defective modules to be replaced without disassembling the entire battery system or removing the housing.

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

The solution reduces manufacturing costs and effort by integrating cooling channels directly into the frame, enhancing cooling performance and structural integrity, thus improving the efficiency and durability of the battery module.

Implementation Method 1

a first metal sheet (32) on an inner side of the plate and a second metal sheet (34) on an outer side of the plate roll-bonded to each other

Methodology Applied

Scientific EffectRoll-bonding:

Implementation Method 2

at least one cooling channel (40, 42) formed by inflation between bonding areas (33) where the first metal sheet (32) and the second metal sheet (34) are roll-bonded

Methodology Applied

Scientific EffectInflation:

Data Source

PatentEP4636906A1Battery module and method of manufacturing the same

Publication Date: 2025.10.22 SAMSUNG SDI CO LTD

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AI summary

The present disclosure refers to a battery module (100) and a method of manufacturing the battery module (100). The battery module (100) includes a plurality of battery cells (10). The frame (20) includes a bottom member (22) and a plurality of side walls (24, 25, 26, 27), wherein the bottom member (22) and the plurality of side walls (24, 25, 26, 27) form an interior accommodation space (28) in which the plurality of battery cells (10) is accommodated. The at least two side walls (24, 26) opposite from each other among the plurality of side walls (24, 25, 26, 27) are bent and extended from the bottom member (22). The at least two side walls (24, 26) and the bottom member (22) are formed by a plate (30) comprising at least one of a first metal sheet (32) and at least one of a second metal sheet (34) roll-bonded to each other. The plate (30) further includes at least one cooling channel (40) formed by inflation between bonding areas (33) where the first metal sheet (32) and the second metal sheet (34) are roll-bonded with each other.