Battery Pack Filling Layout for Faster Heat Dissipation
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Solution Overview
Problem
Existing battery packs face challenges in uniformly filling materials to dissipate heat from densely arranged battery cells, which can lead to overheating, ignition, and explosion, and require significant time and costs.
Innovation Solution
A battery pack design incorporating a frame, cell holders, and a heat sink, where cell holders support battery cell ends and adjust the volume and filling material amount, using a filling material like silicon to fix and cool the cells, and a heat sink to dissipate heat efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If filling material is injected to the space between battery cells to fix and cool them, then heat dissipation is improved and cell fixation is enhanced, but the filling process requires much time and costs, and uniform filling throughout the entire space is difficult to achieve
Solution Approach 1:
The battery pack is divided into multiple layers with battery cells arranged in a specific pattern, creating defined spaces between cells. This segmentation allows filling material to be injected into specific regions rather than requiring complete saturation of the entire space, reducing filling time while maintaining effective heat dissipation and fixation.
Solution Approach 2:
Filling material is selectively injected into specific spaces between battery cells where heat accumulation is most likely to occur, rather than uniformly filling the entire battery pack volume. This local quality approach ensures effective heat dissipation in critical areas while reducing overall material usage and filling time.
2Reliability
If filling material is injected to the space between battery cells to fix and cool them, then heat dissipation is improved and cell fixation is enhanced, but the filling process requires much time and costs
Solution Approach 1:
The battery pack structure is segmented into multiple layers with defined cell arrangements, creating discrete filling spaces. This segmentation reduces the total volume requiring filling material while ensuring stable fixation of cells, thereby reducing material costs and manufacturing complexity.
Solution Approach 2:
Instead of filling the entire space between battery cells, the filling material is injected into specific critical spaces that provide sufficient fixation and heat dissipation. This partial action approach reduces material consumption and manufacturing costs while maintaining the required reliability of cell fixation.
3Quantity of substance
If battery cells are densely arranged to increase output, then space utilization is improved, but heat accumulation occurs leading to overheating and safety risks
Solution Approach 1:
Battery cells are arranged in multiple layers with specific spacing and positioning, creating defined channels and spaces for heat dissipation. This segmented arrangement allows high cell density while maintaining adequate thermal management pathways for heat to escape from each cell.
Solution Approach 2:
Filling material with high thermal conductivity is selectively placed in specific spaces between battery cells where heat accumulation is most critical. This local quality enhancement provides targeted heat dissipation in high-density arrangements, preventing overheating while maintaining space efficiency.
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 stabilizes battery cell fixation, reduces filling material usage, and enhances heat dissipation, improving manufacturing efficiency and safety by minimizing overheating risks.
Implementation Method 1
a heat sink disposed to face one side of the frame, thereby cooling the battery cells
Implementation Method 2
the filling material may fix the battery cells and easily dissipate the heat generated from the battery cells
Data Source
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AI summary
Provided is a battery pack including: a frame having an inner space; a plurality of battery cells each having one end disposed in the inner space of the frame and the other end protruding to the outside of one side of the frame; a filling material filled in the inner space of the frame; a heat sink disposed to face one side of the frame; and a plurality of cell holders stacked between the frame and the heat sink. Here, a volume of the inner space of the frame and an amount of the filling material filled in the inner space of the frame are adjusted according to the stacked number of the cell holders.