Battery Pack Metal Case Cooling With Granular Heat Filler
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Solution Overview
Problem
Existing rechargeable battery designs face issues with overheating, particularly in high-capacity Lithium-Ion cells, leading to over-temperature shutdowns and potential damage, and conventional thermal management solutions are not compatible with existing or legacy battery designs.
Innovation Solution
A thermal management system using a metal case with a thermally conductive granular filler and electrically insulating lining, combined with a pressure relief vent, to dissipate heat effectively and maintain electrical isolation, suitable for existing battery designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional battery designs are used with custom solid support members or thermoplastic configurations, then thermal management is improved, but battery volume, weight, and cost increase significantly
Solution Approach 1:
The metal case serves multiple functions: it provides structural support for the battery cells, acts as a thermal management system through its high thermal conductivity, and eliminates the need for separate custom solid support members. This multi-functionality reduces overall battery weight while maintaining effective heat dissipation.
Solution Approach 2:
The invention extracts and eliminates the separate custom solid support members and thermoplastic thermal management components from the battery design. By integrating thermal management directly into the metal case structure, these additional components are removed, reducing battery weight and complexity.
2Temperature
If conventional battery designs are used with custom solid support members or thermoplastic configurations, then thermal management is improved, but battery volume increases
Solution Approach 1:
The metal case serves multiple functions: it provides structural support for the battery cells, acts as a thermal management system through its high thermal conductivity, and eliminates the need for separate custom solid support members. This multi-functionality reduces overall battery volume while maintaining effective heat dissipation.
Solution Approach 2:
The invention merges the structural support function and thermal management function into a single integrated metal case structure. By combining these functions rather than using separate components, the overall battery volume is reduced while maintaining both mechanical support and heat dissipation capabilities.
3Reliability
If charge/discharge current levels are limited to prevent over-temperature shutdown, then battery safety is improved, but power output decreases
Solution Approach 1:
The invention replaces the conventional approach of limiting electrical current to manage thermal issues with a thermal conduction-based solution. The high thermal conductivity metal case actively conducts heat away from the cells, allowing higher current levels to be sustained without overheating, thereby maintaining both safety and power output.
Solution Approach 2:
The metal case acts as an intermediary thermal management system between the battery cells and the environment. It conducts heat away from the cells during high current operation, enabling higher power output while maintaining battery safety through effective thermal mediation rather than current limiting.
4Temperature
If custom solid support members are used for thermal management, then heat dissipation is improved, but device complexity increases
Solution Approach 1:
The metal case serves multiple functions: it provides structural support for the battery cells, acts as a thermal management system through its high thermal conductivity, and eliminates the need for separate custom solid support members. This multi-functionality reduces overall battery weight while maintaining effective heat dissipation.
Solution Approach 2:
The invention merges the structural support function and thermal management function into a single integrated metal case structure. By combining these functions rather than using separate components, the overall battery volume is reduced while maintaining both mechanical support and heat dissipation capabilities.
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
Enables continuous high-rate charging and discharging at elevated temperatures, increasing battery life and safety by reducing thermal impedance and preventing over-temperature shutdowns.
Implementation Method 1
A thermally conductive granular filler occupies the interstices between the individual cells and between the cell pack and the lining. The thermally conductive filler decreases the thermal impedance from the cell pack to the exterior surface of the metal case to reduce cell pack temperature
Implementation Method 2
The support member may include an endothermic material as one of its components. For example, U.S. Patent Application Publication 2017/0214103 and U.S. Patent Application Publication 2018/0375076 include alumina trihydrate in a blend of other minerals
Data Source
AI summary
A thermal management system (270) for rechargeable secondary batteries having an electrically insulating material (262) lining the interior of a metal case (260). One or more cell packs (24) made of individual cells (12) arranged within end frames (220) is disposed in the metal case (260). A thermally conductive granular filler (264) occupies the interstices (264A) between the individual cells (12) and the space between the cell pack and the electrically insulating material liner (262). The thermally conductive filler (264) decreases the thermal impedance from the cell pack (24) to the exterior surface of the metal case (260) to reduce cell pack temperature and increase battery life