General Motors is currently exploring a new approach to configuring prismatic battery cells to enhance their cooling capabilities.
In a patent filing published by the United States Patent and Trademark Office (USPTO) on Dec. 26, 2024 (originally filed by GM on Jun. 23, 2023), General Motors details a unique method of stacking layers in an inverted “U” shape, as opposed to the conventional rolled or stacked layers used in current prismatic cells.
This innovative configuration aims to improve thermal conductivity in both the horizontal and vertical directions within the cell, resulting in better heat dissipation and potentially enhancing the effectiveness of cooling systems when integrated into a battery pack, according to GM’s claims.
General Motors inverted U prismatic battery cell patent image
The inverted “U” stack also prolongs thermal delay time within the cell, allowing heat to dissipate more gradually. This design feature is intended to keep peak temperatures lower even in the event of overheating, potentially containing the heat more effectively. GM asserts that this design enables a 50% thinner thermal response barrier.
This new cell format could potentially lead to reducing cell size or increasing energy density by optimizing the space for active material. Additionally, the reduced cooling requirements may allow for smaller pack sizes in future designs.
Although this innovative cell format offers significant benefits, it also poses manufacturing challenges due to its complex shape, which may explain why major battery manufacturers have not yet adopted this approach.
General Motors inverted U prismatic battery cell patent image
General Motors is already exploring the use of pouch, cylindrical, and prismatic cell formats simultaneously in its electric vehicles, highlighting the importance of flexibility. The company has also considered unconventional cell shapes in previous patents to enhance cooling efficiency.
While companies like Tesla, Lucid, and Rivian focus on cylindrical cells for their EVs, General Motors’ innovative approach to prismatic cell configuration demonstrates its commitment to advancing battery technology for improved performance and efficiency.