Arc-Shaped Battery Pack Cell Arrangement for Thermal Management
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Solution Overview
Problem
Lithium-ion battery packs with nominal voltages higher than 36V often have a large volume due to multiple cells connected in parallel, leading to uneven temperature distribution and reduced discharge capacity over time, as inner cells experience poor heat dissipation compared to outer cells during high-power discharge.
Innovation Solution
A battery pack design featuring a housing with a battery assembly comprising cells arranged in arc-shaped single-row sets, where each set's axes are on a circular arc, with triangular alignment between adjacent sets, and varying gap sizes between cells to enhance heat dissipation, allowing for better airflow and uniform temperature distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If cells are arranged in multiple rows with more cells to increase voltage, then the battery pack voltage increases, but the inner cells have poor heat dissipation compared to outer cells
Solution Approach 1:
The patent applies curvature by arranging cell axes on a circular arc instead of straight lines, creating a curved battery pack structure. This curvature allows heat to dissipate more uniformly across all cells including inner cells, as the curved arrangement improves thermal contact with the housing and eliminates the heat dissipation disparity between inner and outer cells that exists in linear multi-row arrangements
2Power
If more cells are connected in parallel to increase voltage above 36V, then the battery pack voltage increases, but the volume of the battery pack becomes larger
Solution Approach 1:
The curved arrangement of cells on a circular arc allows for more compact space utilization compared to traditional linear arrangements. This curvature enables the battery pack to achieve higher voltage through parallel connections while maintaining a smaller overall volume, as the curved structure reduces the linear footprint and allows cells to be packed more efficiently in three-dimensional space
3Volume of stationary object
If cells are arranged in a compact configuration to reduce volume, then the battery pack volume decreases, but the temperature difference between cells increases
Solution Approach 1:
The curved arrangement on a circular arc maintains compact volume while ensuring uniform heat dissipation across all cells. The curvature geometry allows each cell to have optimal thermal contact with the housing structure, preventing temperature differences even in compact configurations where inner and outer cells would otherwise have significantly different thermal conditions
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 design results in a compact, stable, and reliable battery pack with reduced temperature differences between cells, improving discharge capacity and extending the battery's lifespan by ensuring uniform heat dissipation without the need for additional heat dissipation materials, thus reducing manufacturing costs.
Implementation Method 1
the housing comprises an upper housing and a lower housing that are vertically arranged; the upper housing defines an air inlet, the lower housing defines an air outlet, and the battery assembly is disposed between the air inlet and the air outlet
Data Source
AI summary
A battery pack, including a housing and at least one battery assembly disposed within the housing; wherein each battery assembly includes a plurality of cells and a cell bracket connected to longitudinal ends of the plurality of cells; wherein along a longitudinal view, the plurality of cells are divided into at least two single-row cell sets, and axes of cells in each single-row cell set are on a same arc of a circular arc; axes of two adjacent cells in one of the at least two single-row cell sets are in a triangular shape with an axis of a corresponding cell in another of the at least two single-row cell sets, the one of the at least two single-row cell sets being adjacent to the another of the at least two single-row cell sets.