Battery Pack Coating Stackup for Structural Load and Heat Transfer
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Solution Overview
Problem
Traditional battery packs are ill-equipped to support large mechanical loads and efficiently transfer heat, limiting their integration with systems that require such capabilities.
Innovation Solution
A battery pack design featuring a stacked assembly with a structural adhesive and thermal adhesive between battery cells and enclosure walls, along with an enclosure coating, to structurally couple and electrically isolate cells while promoting heat transfer through a heat exchanger.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional battery pack configurations are used, then the battery pack can be manufactured with simple structures, but the battery pack cannot support large mechanical loads from heavy componentry
Solution Approach 1:
The patent applies composite materials by combining multiple functional coatings (enclosure coating, cell coating) with specialized adhesives (structural adhesive, thermal adhesive) to create a multi-layered interface system. This composite structure enables simultaneous mechanical load support, electrical isolation, and thermal management, resolving the contradiction between strength enhancement and structural complexity.
Solution Approach 2:
The coating and adhesive assemblies serve multiple functions simultaneously: structural coupling for mechanical strength, electrical isolation for safety, and thermal conduction for heat dissipation. This multi-functionality allows a single integrated system to address multiple requirements without proportionally increasing complexity.
2Temperature
If traditional battery pack configurations are used, then the manufacturing process is simple, but heat transfer from the battery pack to the external environment is limited
Solution Approach 1:
The thermal adhesive acts as an intermediary material between the battery cell and enclosure, facilitating efficient heat transfer while maintaining structural integrity. This mediator enables thermal management functionality without requiring complex cooling systems, addressing the heat transfer limitation.
Solution Approach 2:
The patent applies different adhesive types at different locations: structural adhesive for mechanical coupling and thermal adhesive for heat dissipation. This localized functional differentiation optimizes heat transfer efficiency at critical interfaces while maintaining overall structural performance.
3Reliability
If battery cells are directly coupled with enclosure walls, then the structure is simple, but electrical isolation between battery cells and enclosure is insufficient
Solution Approach 1:
The interface between battery cell and enclosure is segmented into multiple functional layers: enclosure coating, structural adhesive layer, thermal adhesive layer, and cell coating. This segmentation allows each layer to specialize in one function (protection, mechanical bonding, thermal management, or electrical isolation), achieving reliable electrical isolation through cumulative effect of multiple layers.
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 design enhances mechanical load support and heat transfer, improving the battery pack's integration with systems by distributing mechanical loads effectively and increasing strength against mechanical loads by up to four times that of traditional configurations.
Implementation Method 1
a structural adhesive disposed between a first cell coating portion of the cell coating and a first enclosure coating portion of the enclosure coating
Implementation Method 2
a thermal adhesive disposed between a second cell coating portion of the cell coating and a second enclosure coating portion of the enclosure coating
Implementation Method 3
a heat exchanger forming a portion of the enclosure or coupled to the enclosure such that the second enclosure coating portion is between the heat exchanger and the thermal adhesive
Data Source
AI summary
A battery pack includes an enclosure comprising a first wall and a second wall opposing the first wall, battery cells disposed in an interior of the enclosure between the first wall and the second wall, a first coating and adhesive assembly, and a second coating and adhesive assembly. The first coating and adhesive assembly is configured to structurally couple the battery cells with the first wall of the enclosure and electrically isolate the battery cells from the first wall of the enclosure. The second coating and adhesive assembly is configured to structurally coupling the battery cells with the second wall of the enclosure and electrically isolate the battery cells from the second wall of the enclosure.