Battery Assembly Thermal Management via Integrated Circuit Board
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Solution Overview
Problem
Existing battery modules face challenges in heat dissipation, particularly at high power usage, due to independent components like bus bars, fuses, and cooling pipes requiring additional space and not effectively managing thermal management.
Innovation Solution
A method for manufacturing a battery assembly that integrates thermally conductive adhesives and sheets within a copper clad laminate structure, forming cavities for improved heat dissipation and bending flexibility, allowing for efficient heat transfer and reduced component spacing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If independent components (bus bars, fuses, cooling pipes) are used for current collection and thermal management, then over-current protection and cooling functions are achieved, but additional space is required and heat dissipation effectiveness is insufficient
Solution Approach 1:
The patent merges multiple independent components (bus bars, fuses, cooling pipes) into an integrated circuit board structure. The copper layers serve as both current collection paths and heat dissipation channels, while cavities provide cooling channels, eliminating the need for separate components and reducing space occupation.
Solution Approach 2:
The circuit board is designed to perform multiple functions simultaneously: current collection through copper layers, thermal management through integrated cooling channels, and structural support. This multi-functional design replaces multiple specialized components with a single versatile structure.
2Temperature
If cooling pipes are installed at both ends of battery cells, then cooling function is provided, but heat dissipation requirements at high power are not met
Solution Approach 1:
The patent transitions from one-dimensional cooling (pipes at ends) to two-dimensional cooling by integrating cooling channels throughout the circuit board structure. The cavities and copper layers create a distributed thermal management system that contacts the battery cell along its entire length, significantly improving heat dissipation capability.
3Temperature
If thermally conductive adhesives and sheets are integrated within copper clad laminate structure, then heat dissipation performance is enhanced and space is optimized, but manufacturing complexity increases
Solution Approach 1:
The thermally conductive adhesives and sheets are pre-integrated into the copper clad laminate structure during circuit board manufacturing. This preliminary integration ensures optimal thermal contact and eliminates the need for separate assembly steps, actually simplifying the overall manufacturing process while maintaining heat dissipation performance.
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 enhances heat dissipation performance, reduces weight, and optimizes space usage by integrating heat dissipation areas and bending areas within the battery assembly, ensuring effective thermal management and safety during high-power operations.
Implementation Method 1
a plurality of thermally conductive adhesive blocks (25) are disposed on the surface of the first dielectric layer (22)
Implementation Method 2
The cavities (45a) are at least located in the heat dissipation areas (I) and are filled with liquid
Data Source
AI summary
A battery assembly includes a circuit board and a battery cell. The circuit board includes a first dielectric layer, a second dielectric layer, an adhesive film, a bus bar, a first copper block, a fuse, and a second copper block. The adhesive film is located between the first dielectric layer and the second dielectric layer and includes cavities. The first copper block and the bus bar are on the first dielectric layer. The second copper block and the fuse are on the second dielectric layer. The circuit board is divided into heat dissipation areas and bending areas which are connected and alternately arranged, the heat dissipation areas and the bending areas enclose a holding groove. The bus bar and the first block copper are accommodated in the holding groove. The battery cell is accommodated in the holding groove. A battery module and a manufacturing method are also disclosed.