Battery Pack Heat Radiation Molding for Cell Temperature Rise
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Solution Overview
Problem
Conventional battery packs face challenges in managing heat distribution efficiently, leading to potential thermal runaway, and require large amounts of potting resin, which increases weight and manufacturing complexity.
Innovation Solution
A battery pack design incorporating pre-formed, flexible heat radiation molding made of materials that melt through endothermic reactions, strategically positioned to cover secondary battery cells, reducing weight and simplifying manufacturing by eliminating the need for extensive potting resin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If potting resin is used to fill gaps between battery cells for heat management, then heat distribution is improved, but battery pack weight increases
Solution Approach 1:
The patent applies local quality by placing heat radiation moldings only at specific locations where heat accumulation occurs, rather than filling the entire battery pack with potting resin. The moldings are positioned in gaps between battery cells and at heat-prone areas, providing targeted heat management while minimizing material usage and weight increase.
Solution Approach 2:
The heat management system is segmented into multiple discrete heat radiation moldings rather than using a continuous potting resin filling. Each molding is an independent component placed at specific locations, allowing for modular assembly and reduced overall material quantity while maintaining effective heat distribution.
2Temperature
If potting resin is used to fill the waterproof container, then heat conduction is improved, but manufacturing time increases
Solution Approach 1:
The heat radiation moldings are pre-formed into specific shapes and sizes before assembly. This preliminary preparation allows for quick placement into predetermined positions during battery pack assembly, eliminating the time-consuming processes of pouring, filling, and curing potting resin while ensuring proper heat conduction pathways are established.
Solution Approach 2:
The patent extracts the heat conduction function from the potting resin process and implements it through discrete heat radiation moldings. This removes the time-consuming resin filling and curing steps while maintaining the essential heat conduction capability through strategically placed moldings made of heat-conductive materials.
3Temperature
If potting resin is used throughout the battery assembly, then heat radiation is achieved, but device complexity increases
Solution Approach 1:
The heat radiation function is segmented into multiple discrete moldings rather than requiring a continuous potting resin application. Each molding is a simple, pre-formed component that can be independently positioned and secured, significantly simplifying the manufacturing process compared to resin injection, distribution, and curing operations.
Solution Approach 2:
Heat radiation capability is applied locally at specific positions where it is most needed, rather than uniformly throughout the entire battery assembly. This targeted approach reduces the complexity of the manufacturing process by eliminating the need for comprehensive resin filling while maintaining effective heat radiation at critical locations.
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 solution effectively manages heat distribution by melting to absorb heat, reducing weight and manufacturing complexity while maintaining high heat transfer performance, thus preventing thermal runaway and improving battery pack efficiency.
Implementation Method 1
the heat radiation molding is made of a material that melts by an endothermic chemical reaction
Implementation Method 2
designed to melt in response to heat generated from the at least one secondary battery cell
Implementation Method 3
the battery pack allows conduction of the heat to components such as the other secondary battery cells via the potting resin
Data Source
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AI summary
Provided is a battery pack that is given a function for hindering a rise in secondary battery cell temperature by a simple technique. A battery pack includes a battery assembly (10), a heat radiation molding (20) being molded in advance and having flexibility, and an external case housing the battery assembly (10). The battery assembly (10) includes at least one secondary battery cell (1) and a battery holder (11) to hold and house the at least one secondary battery cell (1). A heat radiation molding (20) covers a surface of the at least one secondary battery cell (1) and is designed to melt in response to heat generated from the at least one secondary battery cell (1). As compared with the conventional technique of putting a potting resin throughout a battery assembly, the configuration described above enables any portion to have a heat radiation property by disposing the heat radiation molding (20) at a portion required to have the heat radiation property. This contributes to a reduction in volume of the heat radiation molding (20) and a reduction in weight of the battery pack, enabling simplification of a manufacturing process for the battery pack.