Battery Pack Cooling via Thermally Conductive Cell Retainer

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Solution Overview

Problem

Battery packs used in outdoor power equipment face challenges in managing heat generated during high discharge and charging rates, which can lead to excessive temperatures and reduce their operational life, especially when exposed to harsh environments, and traditional active cooling methods can introduce noise and contaminants.

Innovation Solution

A battery pack design featuring a cell retainer made of thermally conductive material that accumulates and transfers heat to an external heat exchanger, providing passive or active cooling without internal cooling apparatus, thus preventing excessive temperature buildup and protecting the cells from contaminants.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If battery cells are sealed in a cell retainer to protect from environmental contaminants, then reliability is improved, but heat dissipation becomes difficult and temperature increases

Engineering Contradiction:

Improveprotection from environmental contaminantsVSAvoidcell temperature

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

A thermally conductive material is introduced as an intermediary between the battery cells and the cell retainer. This material facilitates heat transfer from the cells to the retainer while the retainer maintains its sealed protective function, thus resolving the contradiction between protection and heat dissipation.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces active mechanical cooling systems with passive thermal conduction through the cell retainer and thermally conductive material. This substitution eliminates the need for complex active cooling mechanisms while effectively managing heat dissipation in a sealed environment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Temperature

If active cooling apparatus is installed inside the cell retainer to dissipate heat, then temperature is reduced, but device complexity and exposure to contaminants increase

Engineering Contradiction:

Improvecell temperatureVSAvoidinternal cooling apparatus

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The cooling function is extracted from the internal cell retainer environment and placed externally. The cell retainer itself becomes the heat dissipation pathway through thermal conduction, eliminating the need for internal cooling apparatus and maintaining the sealed protective environment.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The cell retainer structure itself is designed to provide thermal management functionality. By incorporating thermally conductive material and designing the retainer as a heat sink, the system uses its own structure for cooling without requiring separate active cooling components.

Inventive Principle:

Principle #25Self-service

3Productivity

If high discharge rates are used to increase power output, then productivity is improved, but heat generation increases and operational life decreases

Engineering Contradiction:

Improvepower outputVSAvoidoperational life

Core Design Contradiction:

ProductivityVSDuration of action of moving object

Solution Approach 1:

The heat generated by high discharge rates is converted from a harmful byproduct into a manageable thermal flow. The thermally conductive material and cell retainer design channel this heat away from the cells, allowing high power output to be sustained without compromising operational life through excessive temperature buildup.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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

This design enhances the operational life and performance of battery packs by effectively managing heat without exposing the cells to environmental contaminants or noise-inducing active cooling, while maintaining performance across varying temperature ranges.

Implementation Method 1

The cell retainer may be in thermal communication with the battery cells to transfer heat away from the battery cells

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

The heat exchanger assembly may be in thermal communication with the cell retainer and external to the cell retainer to at least passively transfer heat away from the cell retainer

Methodology Applied

Scientific EffectHeat transfer: Heat Exchanger

Data Source

PatentUS11495840B2Apparatus for providing battery pack cooling

Publication Date: 2022.11.08 HUSQVARNA AB

AI summary

A battery pack may include a plurality of battery cells, a cell retainer and a heat exchanger assembly. The cell retainer may define a plurality of cell reception slots configured to retain respective ones of the battery cells. The cell retainer may define an enclosure that fixes the battery cells and is not penetrated by any cooling apparatus. The cell retainer may be in thermal communication with the battery cells to transfer heat away from the battery cells. The heat exchanger assembly may be in thermal communication with the cell retainer and external to the cell retainer to at least passively transfer heat away from the cell retainer while the battery pack is operated in a discharge mode. The cell retainer may include a thermally conductive material capable of transferring heat to the heat exchanger assembly and also storing at least some of the heat.