Battery Pack Thermal Interface for Easy Cell Stack Separation
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Solution Overview
Problem
Existing battery packs with partially exposed battery cells or cell-to-pack (CTP) configurations face challenges in achieving uniform thermal conduction efficiency, requiring separate pressure for contact, and difficulty in separating the battery cell stack from the pack without damage.
Innovation Solution
A battery pack design featuring a heat transfer portion with a thermal resin bonded to the battery cell stack, an insulating film between the thermal resin and the heat sink, and the option to include carbon nanotubes for enhanced heat conduction, allowing for uniform contact and easy separation of the battery cell stack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If thermal resin is used to bond the lower part of the battery pack with the battery cell for heat transfer, then thermal conduction efficiency is improved, but the battery cell becomes difficult to separate from the battery pack
Solution Approach 1:
The bonding structure is divided into two distinct segments: a reusable lower part of the battery pack and a disposable battery cell. The lower part contains the thermal resin bonding layer that can be reused, while the battery cell is designed to be easily replaceable. This segmentation allows the thermal resin to provide strong bonding for heat transfer while enabling straightforward separation when the battery cell needs replacement.
Solution Approach 2:
The thermal resin bonding layer acts as an intermediary between the lower part of the battery pack and the battery cell. It provides the necessary thermal conduction while allowing for controlled separation. The insulating film serves as another intermediary layer that facilitates easy separation by providing a non-adhesive interface between the thermal resin and the battery cell's lower cover.
2Temperature
If the lower part of the battery pack is fixed in tight contact with the battery cell for heat transfer, then heat transfer efficiency is improved, but the battery pack structure becomes more complex
Solution Approach 1:
The thermal resin bonding layer combines multiple functions into a single integrated component: it provides thermal conduction, structural bonding, and heat dissipation pathways. By merging these functions into one layer rather than using separate components for each function, the design achieves effective heat transfer without increasing overall structural complexity.
Solution Approach 2:
The lower part of the battery pack is designed with multi-functionality: it serves as both the structural base and the heat dissipation component. The thermal resin bonding layer simultaneously provides mechanical attachment and thermal conduction, eliminating the need for separate fastening mechanisms and simplifying the overall structure.
3Ease of operation
If an insulating film is added between the thermal resin and heat sink to enable easy separation, then ease of separation is improved, but the distance to heat sink increases reducing thermal efficiency
Solution Approach 1:
An ultra-thin insulating film is used between the thermal resin bonding layer and the battery cell's lower cover. This thin film provides sufficient electrical insulation and separation capability while minimizing the increase in distance between the heat-generating battery cell and the heat sink, thereby maintaining effective thermal conduction.
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 achieves uniform thermal conduction efficiency without the need for separate pressure, minimizes distance to the heat sink for improved heat transfer, maintains insulation performance with minimal thickness, and allows for easy removal of the battery cell stack from the pack.
Implementation Method 1
a heat transfer portion (260) bonded to the battery cell stack (220), the heat transfer portion comprising a thermal resin
Implementation Method 2
an insulating film (290) between the heat transfer portion (260) and the heat sink (280)
Implementation Method 3
a heat sink (280) disposed so as to face the heat transfer portion (260), the heat sink (280) being configured to discharge the heat
Implementation Method 4
the option to include carbon nanotubes for enhanced heat conduction
Data Source
AI summary
An easy-to-disassemble battery pack is configured to have a structure in which an insulating film is added between a thermal resin and a heat sink such that a lower part of the battery pack is separable from a battery cell while the lower part of the battery pack is fixed in tight contact with the battery cell for heat transfer.