Battery Pack Dividing Walls for Thermal Management
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Solution Overview
Problem
High-power battery packs for electric vehicles face accelerated degradation due to temperature differences among batteries, leading to uneven battery characteristics and reduced lifespan, with existing solutions being costly and complex in manufacturing.
Innovation Solution
A battery pack design featuring circular cylindrical batteries arranged in multiple rows and columns with thermally coupled battery holders made of insulating plastic, where the dividing walls have varying thickness to enhance heat dissipation, and potting resin is used to improve thermal coupling between batteries and holders, allowing efficient heat transfer and dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If batteries are disposed in multiple rows and columns connected in series and parallel for high power applications, then output voltage and current are increased, but battery temperature differences develop causing non-uniform battery characteristics and accelerated degradation
Solution Approach 1:
The battery holder employs dividing walls with non-uniform thickness distribution, where the thickness varies in the row direction to create different thermal capacities at different locations. This local quality variation allows the holder to provide enhanced heat absorption at critical positions (center regions) while maintaining overall structural integrity, thereby addressing temperature differences without compromising the high power output capability
2Temperature
If insulating oil is used to immerse batteries for heat transfer, then battery temperature differences are reduced, but manufacturing cost increases due to complex water-tight external case requirements
Solution Approach 1:
The invention extracts the heat transfer function from the complex external case structure and relocates it to the battery holder component. The battery holder with varying thickness dividing walls serves as an integrated heat management component, eliminating the need for separate insulating oil reservoirs and complex water-tight case structures, thereby reducing manufacturing complexity and cost while maintaining effective temperature control
Solution Approach 2:
The battery holder is designed to perform multiple functions simultaneously: mechanical support for batteries, structural organization through dividing walls, and thermal management through heat absorption and dissipation. This multi-functionality consolidates several components into one, simplifying the overall structure and reducing manufacturing cost while achieving effective temperature uniformity
3Temperature
If hollow metal is disposed conforming to battery surfaces and filled with heat transfer cement, then heat transfer is improved, but fabrication becomes difficult and manufacturing cost increases
Solution Approach 1:
The invention replaces expensive and difficult-to-fabricate hollow metal structures with a simpler, more economical battery holder design made from conventional materials. The varying thickness dividing walls provide effective heat management without requiring complex metal forming and cement filling processes, significantly reducing fabrication difficulty and manufacturing cost while maintaining adequate heat transfer performance
4Ease of manufacture
If dividing walls are made with uniform thickness, then manufacturing is simplified, but heat capacity is insufficient at center regions causing temperature differences
Solution Approach 1:
The dividing walls are designed with non-uniform thickness where the thickness varies in the row direction, creating regions of different thermal capacity. The center regions have greater thickness and heat capacity to absorb more heat from centrally located batteries, while peripheral regions have lesser thickness. This local quality variation optimizes heat management for the specific thermal distribution pattern in multi-row battery configurations
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 effectively reduces temperature differences between batteries, prolongs the battery pack's lifespan, and simplifies manufacturing, making it more cost-effective for high-power applications like electric motor-bikes.
Implementation Method 1
Each battery contacts the dividing walls in a thermally coupled manner to transfer and dissipate heat generated by the batteries to the battery holders
Implementation Method 2
potting resin is used to improve thermal coupling between batteries and holders, allowing efficient heat transfer and dissipation
Data Source
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AI summary
The battery pack has a plurality of batteries 1, and battery holders 2 that dispose the batteries 1 in multiple rows and columns and in parallel orientation. The battery holders 2 are provided with insertion sections 21 separated by dividing walls 22 where batteries 1 are inserted and held in fixed positions. Each battery 1 contacts the dividing walls 22 in a thermally coupled manner to transfer and dissipate heat generated by the batteries 1 to the battery holders 2. Further, the thickness of the battery holder 2 dividing walls 22 increases from the periphery (surface) regions to the center regions making the heat capacity of the dividing walls 22 thermally coupled with batteries 1 disposed in center regions of the battery holders 2 greater than the heat capacity of the dividing walls 22 thermally coupled with batteries 1 disposed in periphery regions of the battery holders 2.