Battery Thermal Interface Thickness Control Using Capacitance
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Solution Overview
Problem
In battery systems, achieving a uniform and precise thermal connection between heat sources and heat sinks is challenging due to manufacturing-related tolerances and unevenness, which affects temperature distribution and increases production costs and potential for errors in electrical insulation.
Innovation Solution
A method using a placing device with continuous capacitance measurement to monitor and control the layer thickness of an electrically insulating heat-conducting material between the heat source and heat sink, ensuring a prescribed thickness and preventing overdosing, thereby ensuring uniform thermal and electrical properties without additional measures like spacers or protective films.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heat-conducting material is used for thermal connection, then thermal conductivity is improved, but electrical insulation is compromised
Solution Approach 1:
The patent uses composite heat-conducting materials that combine thermal conductivity with electrical insulation properties. The material comprises heat-conducting particles embedded in an insulating matrix, creating a composite structure that simultaneously achieves thermal connection and electrical insulation without requiring additional protective films or spacers.
2Temperature
If layer thickness of heat-conducting material is reduced, then thermal resistance is improved, but electrical insulation is compromised
Solution Approach 1:
The patent changes the material parameters of the heat-conducting material by adjusting the concentration, size, and distribution of heat-conducting particles within the insulating matrix. This allows optimization of both thermal resistance and electrical insulation properties within the same material layer, eliminating the need to increase layer thickness for insulation purposes.
3Ease of manufacture
If manufacturing tolerances are considered, then production flexibility is improved, but thermal connection precision deteriorates
Solution Approach 1:
The patent applies preliminary action by pre-forming the heat-conducting material with optimized particle distribution and embedding insulating elements before the final assembly. This preliminary preparation ensures that even with manufacturing tolerances in component positioning, the thermal connection precision is maintained because the material properties are already optimized for the expected tolerance range.
4Reliability
If additional protective films are used for electrical insulation, then electrical insulation is improved, but device complexity and production costs increase
Solution Approach 1:
The patent merges the thermal conduction and electrical insulation functions into a single integrated material layer. The heat-conducting composite material simultaneously provides both thermal connection and electrical insulation, eliminating the need for separate protective films and reducing overall device complexity and production costs.
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 method allows for precise and uniform thermal connection, reducing material usage, minimizing manufacturing tolerances' impact, and ensuring consistent temperature distribution across battery cells, thereby slowing down aging and reducing production costs.
Implementation Method 1
a distance between an electrically conducting housing surface of the heat source and an electrically conducting heat-transmission surface that is a part of the heat sink or is adjacent to the heat sink, is reduced by compression of an electrically insulating heat-conducting material disposed therebetween
Implementation Method 2
During the placing process, a capacitance measurement using a measuring device is continuously carried out between the housing surface and the heat-transmission surface
Data Source
AI summary
A method and system for thermal connection of a heat source of a battery system to a heat sink of the battery system are provided. The method includes implementing of a placing process using a placing device, wherein a distance between an electrically conducting housing surface of the heat source and an electrically conducting heat-transmission surface that is part of the heat sink or is adjacent to it, is reduced by compression of an electrically insulating heat-conducting material. The method also includes implementing of a continuous measurement of capacitance between the housing surface and the heat-transmission surface during the placing process using a measuring device. Additionally, the method includes monitoring of a layer thickness of the heat-conducting material and controlling of the placing device using a control device until a prescribed layer thickness of the heat-conducting material is attained based on the capacitance measurement.