Battery Pack Exhaust Pipe and Cooling Flow Path Design
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Solution Overview
Problem
Existing battery packs face challenges in efficiently managing heat dissipation and electrical connections, leading to potential electrical shorts and reduced safety, especially in high-voltage configurations.
Innovation Solution
A battery pack design featuring a vertically inverted pattern of battery cells, a cell holder with integrated cooling flow paths, and a zig-zag arrangement of bus bars to reduce potential differences between cells, along with an exhaust pipe system for gas relief, enhancing safety and heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If battery cells are connected in high-voltage configuration to increase power output, then power output is improved, but the risk of electrical shorts and safety issues increases
Solution Approach 1:
The battery pack is divided into multiple battery cell holders that are vertically stacked and separated. Each holder contains a specific number of battery cells arranged in series, creating modular voltage segments. This segmentation allows high-voltage configuration while maintaining safety through physical separation and organized electrical connections between segments.
Solution Approach 2:
Conductive adhesives are used as intermediary materials to connect battery cells within holders and connect adjacent holders electrically. These intermediaries provide controlled electrical connections with inherent insulation properties, reducing the risk of electrical shorts while maintaining high-voltage output capability.
2Quantity of substance
If battery cells are densely packed to increase capacity, then energy density is improved, but heat dissipation becomes difficult
Solution Approach 1:
Cooling flow paths are strategically positioned in specific locations within and between battery cell holders, particularly in the gaps between vertically stacked holders. This local quality approach ensures that heat-generating areas have direct cooling access, maintaining effective heat dissipation even with dense battery cell packing.
Solution Approach 2:
A liquid cooling system using hydraulic principles is implemented with cooling flow paths that circulate coolant through channels formed between battery cell holders and within holders. This hydraulic cooling approach efficiently removes heat from densely packed battery cells by converting thermal energy to fluid flow energy for heat exchange.
3Ease of manufacture
If bus bars are arranged in straight lines to simplify manufacturing, then ease of manufacture is improved, but potential differences between cells increase
Solution Approach 1:
Instead of arranging bus bars in traditional straight lines, the patent uses a zig-zag arrangement where conductive adhesives connect battery cells in an alternating pattern between adjacent holders. This inverted approach to connection geometry equalizes the electrical path lengths and reduces potential differences between cells while remaining manufacturable through automated printing processes.
4Ease of operation
If exhaust pipe is positioned at the bottom to facilitate drainage, then ease of operation is improved, but exhaust gas may contact electrical components
Solution Approach 1:
The exhaust pipe is positioned at the bottom of the battery pack but extends vertically upward through the structure to discharge exhaust gases above the battery cells and electrical components. This dimensional approach allows the exhaust inlet to be at the bottom for drainage efficiency while the discharge outlet is elevated to avoid contact with electrical components, solving both requirements simultaneously.
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 improves heat dissipation, reduces the risk of electrical shorts, and enhances safety by managing voltage differences, resulting in a more reliable and efficient battery pack configuration.
Implementation Method 1
a cooling flow path extending across the battery pack in a column direction parallel to a long side direction of the envelope
Implementation Method 2
an exhaust pipe, wherein the exhaust pipe extends from an outer sider surface of the battery cell holder, and the exhaust pipe is in fluid communication with an exhaust path between the first separation member and an outer side surface of the first cell holder
Data Source
AI summary
A battery pack includes battery cells; a battery cell holder in which the battery cells are accommodated; and an exhaust pipe, wherein the battery cell holder includes a first cell holder to which upper end portions of the battery cells are assembled, a second cell holder to which lower end portions of the battery cells are assembled, and a first separation member on the first cell holder, the exhaust pipe extends from an outer sider surface of the battery cell holder, and the exhaust pipe is in fluid communication with an exhaust path between the first separation member and an outer side surface of the first cell holder.