Structural Battery Pack Adhesive Layout for Edge Heat Transfer
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Solution Overview
Problem
Traditional battery packs face inefficiencies and susceptibility to failure due to expensive and ineffective heat transfer components, which hinder the effective management of heat generated by battery cells.
Innovation Solution
The use of adhesives and gap fillers with varying thermal conductivity constants between the battery cells and the enclosure, where the gap fillers have higher thermal conductivity than the adhesives, to efficiently transfer heat away from the cells while providing structural support, thereby improving both heat dissipation and structural performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional heat transfer componentry is used in battery packs, then heat transfer function is provided, but the components are expensive, inefficient, and susceptible to failure
Solution Approach 1:
The patent combines the heat transfer function with the adhesive material itself, eliminating separate heat transfer components. The adhesive is formulated with thermal conductivity enhancers to perform both bonding and heat dissipation functions simultaneously, reducing component count and improving reliability.
Solution Approach 2:
The adhesive material is designed to serve multiple functions: structural bonding between battery components and heat transfer away from battery cells. This multi-functional approach replaces traditional separate components, reducing system complexity and potential failure points.
2Temperature
If gap fillers with high thermal conductivity are used throughout the entire battery pack, then heat transfer efficiency is improved, but manufacturing cost increases
Solution Approach 1:
The patent applies high thermal conductivity gap filler material only in specific locations where heat transfer is most critical, such as between battery cells and heat sinks, rather than uniformly throughout the entire battery pack. This localized application maintains heat transfer efficiency while reducing material costs.
Solution Approach 2:
Instead of applying gap filler material across the entire surface, the patent uses partial action by concentrating the material only in key thermal pathways, achieving sufficient heat transfer performance with reduced material quantity and cost.
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 configuration enhances heat transfer efficiency and structural performance of the battery pack, balancing cost and efficiency by limiting expensive gap fillers to edges and using adhesives for structural support along sides, thus improving overall battery pack performance.
Implementation Method 1
an adhesive extending between a wall of the enclosure and the stack... includes a first thermal conductivity constant greater than a second thermal conductivity constant of the adhesive
Implementation Method 2
a first gap filler extending between the wall and the stack... includes a first thermal conductivity constant greater than a second thermal conductivity constant of the adhesive... a second gap filler extending between the wall and the stack
Data Source
AI summary
A battery pack includes an enclosure forming an enclosure interior, a stack of battery cells disposed within the enclosure interior, and an adhesive extending between a wall of the enclosure and the stack. The battery pack also includes a first gap filler extending between the wall and the stack, where the first gap filler is disposed adjacent to a first edge of the stack and includes a first thermal conductivity constant greater than a second thermal conductivity constant of the adhesive. The battery pack also includes a second gap filler extending between the wall and the stack, where the second gap filler is disposed adjacent to a second edge of the stack and includes a third thermal conductivity constant greater than the second thermal conductivity constant.