Insulated Battery Pack Air-Layer Structure for Low-Temperature Heat Loss

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Solution Overview

Problem

Existing battery packs face challenges in maintaining effective thermal insulation due to spatial limitations, leading to rapid heat loss, especially in low-temperature environments.

Innovation Solution

The insulated battery pack incorporates an insulating member with two opposing insulating layers and a hollow cavity filled with gas to form an air layer, reducing thermal conduction and enhancing insulation. Additionally, liquid cooling plates are integrated to manage heat effectively.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If traditional insulation measures are used in the battery pack, then the structure is simple and easy to manufacture, but the thermal insulation performance is poor leading to rapid heat loss

Engineering Contradiction:
Improveheat lossVSAvoidinsulation structure complexity
Core Design Contradiction:
Loss of energyVSDevice complexity

Solution Approach 1:

The patent applies composite insulation structure combining multiple materials with different thermal properties. The first insulation layer uses a material with first thermal conductivity, the second insulation layer uses a different material with second thermal conductivity, creating a composite structure that optimizes both insulation performance and spatial utilization. This resolves the contradiction by achieving superior thermal insulation without excessive complexity through material composition rather than simple thickness increase.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The patent implements local quality by differentiating the thermal insulation properties at different locations within the battery pack. The first and second insulation layers are positioned at different locations with different thermal conductivity characteristics, providing localized optimization where high insulation is needed most. This allows the system to achieve overall excellent insulation performance while maintaining reasonable structural complexity.

Inventive Principle:
Principle #3Local quality

2Temperature

If the battery pack operates in low temperature environment, then heating is required to maintain optimal temperature, but poor thermal insulation causes rapid heat loss reducing heating efficiency

Engineering Contradiction:
Improvebattery temperature stabilityVSAvoidheating energy loss
Core Design Contradiction:
TemperatureVSLoss of energy

Solution Approach 1:

The composite insulation structure with layers of different thermal conductivities creates a more effective thermal barrier that reduces heat loss to the external environment. This allows the heating system to maintain battery temperature more efficiently, reducing the energy required for heating in low temperature environments while maintaining temperature stability.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The insulation layers act as intermediary elements between the battery and the external environment, creating thermal resistance that slows heat transfer. This intermediary structure reduces direct thermal exchange with the cold environment, thereby reducing heating energy loss while maintaining battery temperature stability.

Inventive Principle:
Principle #24Intermediary (Mediator)

3Loss of energy

If insulation layer thickness is increased to improve thermal insulation, then heat loss is reduced, but the spatial limitation of the battery case is exceeded

Engineering Contradiction:
Improveheat lossVSAvoidbattery pack volume
Core Design Contradiction:
Loss of energyVSVolume of stationary object

Solution Approach 1:

The patent uses composite insulation layers with different thermal conductivity properties to achieve high insulation performance with reduced total thickness. By combining materials strategically, the system obtains superior thermal resistance without requiring excessive space, thus fitting within the battery case volume constraints while minimizing heat loss.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The patent changes the thermal conductivity parameters of the insulation materials used, selecting materials with optimized thermal properties that provide high insulation efficiency per unit thickness. This allows achieving the required insulation performance within the limited spatial constraints of the battery pack design.

Inventive Principle:
Principle #35Parameter changes

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 significantly improves thermal insulation performance, preventing rapid heat loss and maintaining the battery pack in an optimal temperature range, thereby enhancing stability and reliability of the battery pack and associated electric devices.

Implementation Method 1

a hollow cavity is provided between the two insulating layers, the hollow cavity is filled with gas to form an air layer, so as to reduce thermal conduction between two opposite sides of the air layer

Methodology Applied
Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS20250118827A1Insulated battery pack and thermal management method
Publication Date: 2025.04.10 EVE POWER CO LTD
  • US20250118827A1 patent drawing
  • US20250118827A1 patent drawing
  • US20250118827A1 patent drawing

AI summary

Disclosed in the present disclosure is an insulated battery pack, including a cell set, including a plurality of rows of cells; and an insulating member, provided with two insulating layers. The plurality of rows of the cells are provided on one of the insulating layers, the two insulating layers are provided opposite to each other, a hollow cavity is provided between the two insulating layers, the hollow cavity is filled with gas to form an air layer, so as to reduce thermal conduction between two opposite sides of the air layer.