Scalable, Electrically Insulating TPMS Silicone Cold Plates for Passive Battery Thermal Management

This study introduces a novel class of architected foam structures based on triply periodic minimal surface (TPMS) geometries for passive battery thermal management. Unlike conventional cold plates that rely on active pumping or high-conductivity solid materials, the proposed TPMS-like foams leverage convective fluid transport within a lightweight, electrically insulating polymer matrix. We present the design, fabrication, and experimental characterization of Schwarz Primitive TPMS structures manufactured via injection molding using silicone rubber, which has a comparable quality to additively manufactured polymer cold plates but with significantly lower manufacturing complexity and cost. The TPMS cold plates achieve passive fluid circulation without external pumps, reducing parasitic power consumption while maintaining thermal resistance values of approximately 23.5 K/W. Although its thermal resistance is higher than that of an aluminum plate of the same size (2.7 K/W), the TPMS cold plate is electrically insulating and offers additional safety benefits. Additionally, it can be fabricated from and filled with fire-retardant materials to prevent thermal propagation while maintaining a relatively low temperature gradient. Mechanical compression testing of TPMS foam samples with about 30% solid volume fraction showed a compressive strength of 86.2 kPa at 0.2 strain, equivalent to 30.5% of the compressive modulus of solid silicone (282.6 kPa). Compared to solid silicone plates (thermal resistance is 1420 K/W), the TPMS fluid-filled structures reduce thermal resistance by more than two orders of magnitude. This work establishes design rules, fabrication protocols, and performance benchmarks for TPMS-based passive cooling devices, offering a scalable pathway toward safer, lighter, and more energy-dense battery packs.