Thermally-Conductive Cartridge Battery Pack for Compact Cooling
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Solution Overview
Problem
Existing battery packs face challenges in miniaturization and cost efficiency due to the need for cooling members, cooling channels, and circulating devices, which increase volume and complexity, and require additional insulation and space for cooling mediums.
Innovation Solution
A battery pack design featuring a module assembly of stacked, thermally-conductive cartridges and a pack case made of thermally-conductive material, eliminating the need for separate cooling members and channels, and utilizing natural air circulation for cooling, with thermally-conductive polymers and adhesives for efficient heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling members made of metal material are disposed around secondary batteries, then cooling performance is improved, but volume and structure complexity increase
Solution Approach 1:
The cartridge structure is designed to integrate both mechanical support and thermal management functions. The cartridge body surrounds the secondary battery while incorporating cooling channels that directly contact the battery surface, merging the structural housing and cooling system into a single integrated component that reduces overall complexity.
Solution Approach 2:
The cooling medium serves multiple functions: it cools the secondary battery through thermal conduction, provides structural support for the cartridge assembly, and enables both air cooling and water cooling modes depending on the configuration, making the system multi-functional and adaptable.
2Temperature
If cooling members and cooling channels are added, then cooling performance is improved, but fabrication cost and time increase
Solution Approach 1:
The battery pack is divided into modular units where each cartridge is a separate, standardized component. This segmentation allows for mass production of identical cartridges using injection molding or similar processes, significantly reducing fabrication costs and time compared to custom-made cooling solutions.
Solution Approach 2:
The cooling system allows parameter changes by enabling optional configuration with or without active cooling devices. The basic cartridge structure provides passive cooling, while active cooling can be added as needed, allowing fabrication costs to be optimized based on specific application requirements.
3Temperature
If electrically-conductive metal cooling members are used, then cooling performance is improved, but insulation complexity increases
Solution Approach 1:
An electrically insulating layer is introduced as an intermediary between the electrically-conductive metal cooling member and the secondary battery. This thin insulating coating maintains thermal conduction effectiveness while providing necessary electrical insulation, eliminating the need for complex insulation structures.
Solution Approach 2:
The cartridge is constructed using composite materials that combine thermal conductivity and electrical insulation properties. This may include metal-polymer composites or coated metal structures that provide both cooling performance and electrical isolation in a single material system.
4Temperature
If separate cooling devices such as fans or pumps are used, then cooling performance is improved, but volume and fabrication cost increase
Solution Approach 1:
The cooling system is designed to operate without separate active cooling devices. The cartridge structure itself facilitates natural convection and thermal conduction, allowing the battery pack to self-cool through its structural design without requiring additional fans, pumps, or control systems.
Solution Approach 2:
The cooling channels are designed to utilize natural convection currents and pressure differentials created during battery operation, eliminating the need for mechanical pumps or fans. The fluid dynamics are harnessed passively through proper channel geometry and placement.
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 simplifies the structure, reduces size and fabrication costs, and ensures effective cooling performance without the need for additional cooling components, enhancing assembly efficiency and reducing volume while maintaining excellent cooling capabilities.
Implementation Method 1
a plurality of cartridges (120) configured to be stacked with each other and surround an outer circumference of the secondary batteries at an outer side, the plurality of cartridges being at least partially made of thermally-conductive material; and a pack case having an empty space therein to accommodate the module assembly and at least partially made of thermally-conductive material to discharge heat of the module assembly
Implementation Method 2
a pack case having an empty space therein to accommodate the module assembly and at least partially made of thermally-conductive material to discharge heat of the module assembly
Data Source
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AI summary
Disclosed is a battery pack which has a simple structure, small volume and weight, and efficient cooling performance. The battery pack includes a module assembly including a plurality of secondary batteries, and a plurality of cartridges configured to be stacked with each other and surround an outer circumference of the secondary batteries at an outer side, the plurality of cartridges being at least partially made of thermally-conductive material; and a pack case having an empty space therein to accommodate the module assembly and at least partially made of thermally-conductive material to discharge heat of the module assembly.