Battery Heat Dissipation Insert Using Thermal Bridge

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Solution Overview

Problem

The compact design of battery packs in electric vehicles leads to inadequate heat dissipation, resulting in excessive temperature increases that can damage batteries, reduce performance, and shorten their lifespan, especially when charging or discharging rapidly, and existing solutions like forced convection or thermal fluids have drawbacks such as leakage risks and inefficiencies.

Innovation Solution

A heat dissipation insert comprising a heat pipe and a thermally conductive, electrically insulating thermoplastic composition that effectively transfers heat between batteries without the need for forced convection or thermal fluids, ensuring efficient heat management and preventing temperature extremes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If batteries are arranged close together to save space, then the battery pack becomes more compact, but heat dissipation becomes inadequate

Engineering Contradiction:

Improvebattery pack volumeVSAvoidheat dissipation efficiency

Core Design Contradiction:

Volume of moving objectVSTemperature

Solution Approach 1:

A heat coupling element is introduced as an intermediary substance between adjacent batteries to facilitate heat transfer. This element has thermal conductivity higher than air but electrical conductivity lower than air, allowing it to act as a thermal bridge while maintaining electrical insulation. The heat coupling element fills the gaps between batteries, enabling efficient heat dissipation without requiring increased spacing between battery units.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Temperature

If forced convection is used to improve heat dissipation, then cooling efficiency increases, but device complexity and leakage risks increase

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoidcooling system complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The heat coupling element enables the battery pack to dissipate heat through passive conduction without requiring active cooling systems. The element's thermal properties allow heat to naturally conduct from hotter to cooler regions between batteries, eliminating the need for fans, pumps, or controlled fluid circulation systems that would increase device complexity and potential failure points.

Inventive Principle:

Principle #25Self-service

3Temperature

If thermal fluids are used for heat dissipation, then cooling efficiency improves, but reliability decreases due to leakage risks

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoidsystem reliability

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The patent replaces the mechanical fluid circulation system with a solid or semi-solid heat coupling element that conducts heat through thermal conduction. This substitution eliminates the risks associated with thermal fluids such as leakage, evaporation, and contamination, while maintaining effective heat dissipation. The heat coupling element remains in place between batteries and continuously transfers heat without requiring seals, hoses, or circulation mechanisms.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Temperature

If heat coupling element with high thermal conductivity is used, then heat dissipation improves, but electrical conductivity increases causing short circuit risks

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidelectrical short circuit risk

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The heat coupling element is designed as a composite material or a material with anisotropic properties that provides high thermal conductivity in the direction of heat flow while maintaining low electrical conductivity. This allows the element to function as an effective thermal bridge between batteries while simultaneously providing electrical insulation to prevent short circuits. The material composition is specifically selected or engineered to decouple thermal and electrical conductivity properties.

Inventive Principle:

Principle #40Composite materials

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 prevents battery temperatures from exceeding 60°C and reduces thermal gradients within the pack, enhancing battery longevity, safety, and enabling electric vehicles to match the range and charging speed of internal combustion engine vehicles without the risks of thermal fluid leakage.

Implementation Method 1

The insert comprises a heat pipe and a heat coupling element

Methodology Applied

Scientific EffectHeat pipe: Heat Pipe

Implementation Method 2

a thermally conductive, electrically insulating thermoplastic composition that effectively transfers heat between batteries

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Implementation Method 3

a thermally conductive, electrically insulating thermoplastic composition that effectively transfers heat between batteries

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentEP3815170B1Device for removing heat from an array of rechargeable electrochemical energy storage devices

Publication Date: 2023.07.26 COVESTRO INTELLECTUAL PROPERTY GMBH & CO KG

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AI summary

The invention relates to a device for dissipating heat from an arrangement of rechargeable electrochemical energy accumulators. Said device comprises a heat pipe and a heat coupling element. The invention also relates to an arrangement of rechargeable electrochemical energy accumulators, which comprise the claimed device.