Lithium-Ion Battery Pack Structure for Heat Dissipation and Stability
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Solution Overview
Problem
Lithium-ion batteries face safety hazards due to thermal abuse and mechanical stresses, with existing designs often relying on inefficient convection-based heat dissipation and lacking adequate mechanical protection, which can lead to thermal runaway, explosions, or fires.
Innovation Solution
The implementation of a battery management system with improved thermal cooling through conductive heat transfer using thermal resin and structural enhancements such as a stability cage and adhesive restraints to prevent mechanical damage, ensuring efficient heat dispersion and stability during use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If convection-based heat dissipation is used in battery management systems, then the system structure is simpler, but thermal management efficiency deteriorates
Solution Approach 1:
The patent replaces the convection-based thermal management system with a conduction-based system using phase change materials. Instead of relying on air flow and convection currents to dissipate heat, the invention uses PCM to absorb heat through phase change (solid to liquid) and conducts it away through thermal contact, fundamentally substituting the heat transfer mechanism to achieve superior thermal management efficiency.
Solution Approach 2:
The patent utilizes phase change materials that transition from solid to liquid state to absorb and store thermal energy from the battery. This phase transition mechanism provides high heat absorption capacity during charging operations, effectively managing temperature without requiring complex active cooling systems, thus improving thermal efficiency while maintaining relatively simple system architecture.
2Power
If lithium-ion batteries operate at higher currents, then power output increases, but thermal runaway risk increases
Solution Approach 1:
The patent employs phase change materials positioned in thermal contact with the battery cells to absorb the increased heat generation that occurs during high-current operation. The PCM undergoes phase transition at temperatures below thermal runaway thresholds, providing a passive safety mechanism that prevents temperature escalation even when the battery operates at elevated power levels, thus enabling high power output while maintaining thermal safety.
3Stability of the object's composition
If battery cells are secured with adhesive restraints, then mechanical stability improves, but manufacturing complexity increases
Solution Approach 1:
The patent combines multiple functions into the battery housing structure itself. The housing serves as both the enclosure and the mechanical restraint system through integrated features such as recesses, protrusions, and adhesive application surfaces. This merging of structural and restraining functions provides mechanical stability while avoiding the need for separate restraint components, thereby maintaining ease of manufacture.
4Strength
If a stability cage is added to protect battery cells, then mechanical protection improves, but device complexity increases
Solution Approach 1:
The patent designs the battery housing to perform multiple functions simultaneously: it serves as the protective enclosure, the mechanical restraint system, the thermal management interface, and the structural support. This multi-functionality eliminates the need for separate stability cages or protective frameworks, providing comprehensive mechanical protection while maintaining simple overall device architecture.
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 solution enhances thermal and mechanical stability, allowing lithium-ion batteries to operate safely at higher currents and withstand external forces, reducing the risk of thermal runaway and mechanical failure.
Implementation Method 1
a thermal epoxy contacting the one or more thermal components and the battery housing
Implementation Method 2
the first and the second surfaces each include an adhesive component
Data Source
AI summary
A battery configured to have improved thermal management and structural stability. The battery including a battery pack construction with at least one battery cell spacer having a first surface contacting substantially all of the bottom surface of a first battery cell and a second surface contacting substantially all of the top surface of a second battery cell, the battery cell spacer including an adhesive component. Additionally, the battery may include a battery management system (BMS) in electrical communication with the first and second battery cells, the BMS having one or more thermal components configured to disperse heat from the BMS, and a thermal epoxy contacting the one or more thermal components and a battery housing. The battery further including a stability cage at least partially enclosing the battery pack construction and positioned between the battery cells and the battery housing.