Battery Housing Layout for Thermal Isolation of Cells and PCB
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Solution Overview
Problem
The limited space in electric tools for installing batteries leads to heat dissipation issues between cells and circuit boards, risking battery performance deterioration and potential burning or explosion.
Innovation Solution
A battery design with a shell comprising a first, second, and third housing, where the second housing isolates the cell module from the circuit board, forming separate cavities to thermally separate them, and includes features like collecting pieces, channels, and fasteners for electrical connections and thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If cells and circuit board are placed in limited space together, then battery capacity is improved, but heat dissipation performance deteriorates
Solution Approach 1:
The battery housing is divided into multiple independent cavities: a first cavity for accommodating cells and a second cavity for accommodating the circuit board. This segmentation physically separates the heat-generating cells from the heat-sensitive circuit board, allowing independent thermal management for each component while maintaining compact overall structure.
Solution Approach 2:
A collecting piece is introduced as an intermediary component that electrically connects the cells and circuit board while providing thermal isolation. The collecting piece acts as a mediator that allows electrical connectivity without direct thermal contact between the cells and circuit board, resolving the contradiction between electrical connection and thermal separation.
2Volume of moving object
If cells and circuit board are placed close together, then device compactness is improved, but reliability deteriorates due to heat-related risks
Solution Approach 1:
The internal space is segmented into distinct thermal zones using separate cavities for cells and circuit board. This segmentation maintains compact external dimensions while creating internal thermal barriers that prevent heat transfer, thereby improving reliability without sacrificing compactness.
Solution Approach 2:
The housing structure uses thin-walled cavities and partitions that provide thermal isolation while occupying minimal space. These thin film-like structural elements effectively separate thermal zones without significantly increasing the overall device volume, maintaining compactness while enhancing safety.
3Temperature
If thermal isolation structure is added, then heat dissipation performance is improved, but device complexity increases
Solution Approach 1:
The housing is segmented into functional cavities that serve dual purposes: structural organization and thermal isolation. This segmentation integrates the thermal management function into the existing structural framework rather than adding separate isolation components, thereby improving heat dissipation without proportionally increasing complexity.
Solution Approach 2:
The housing structure performs multiple functions simultaneously: it provides mechanical support, defines internal cavities for component mounting, and creates thermal barriers through cavity separation. This multi-functionality reduces the need for additional dedicated thermal isolation components, maintaining structural simplicity while achieving effective heat dissipation.
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
Effectively reduces heat-induced interference between the cell module and circuit board, enhancing battery performance and safety by preventing overheating and potential explosions.
Implementation Method 1
the second housing isolates the cell module from the circuit board
Data Source
AI summary
A battery includes a shell, a cell module, and a circuit board. The shell includes a first housing, a second housing, and a third housing. The cell module includes a plurality of stacked cells. The circuit board is electrically connected to the cell module. The second housing and the first housing close in to form a first cavity. The first cavity is configured to accommodate the cell module. The third housing and the second housing close in to form a second cavity. The second cavity is configured to accommodate the circuit board. Along a stacking direction of the cells, the second housing isolates the cell module from the circuit board. The cell module and the circuit board are disposed in the first cavity and the second cavity respectively. The second housing isolates the circuit board from the cells in the stacking direction of the cells.