Foamed Battery Pack Matrix for Weight and Heat Dissipation
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Solution Overview
Problem
Rechargeable battery packs for electric vehicles face a trade-off between weight reduction and maintaining sufficient thermal conductivity for heat dissipation, with existing solutions either increasing weight or reducing heat exchange efficiency.
Innovation Solution
A synthetic resin matrix with compact outer areas and foamed inner areas is used, incorporating a solid filling agent with high thermal conductivity and a foaming agent to create an expanded structure that reduces weight while maintaining effective heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a compact resin matrix is used to fix batteries, then thermal conductivity is improved for heat dissipation, but weight of the battery pack increases significantly
Solution Approach 1:
The patent applies local quality by creating a resin matrix with non-uniform density distribution: compact outer zones adjacent to battery surfaces for optimal heat conduction, and foamed inner zones for weight reduction. This spatial variation in material density allows each region to fulfill its specific function - heat dissipation near the source and weight reduction in the bulk.
Solution Approach 2:
The patent employs composite materials by combining resin with foaming agents to create a heterogeneous matrix structure. The resulting material integrates both dense regions (for thermal conductivity) and porous foamed regions (for low weight), achieving a composite structure that simultaneously satisfies conflicting thermal and weight requirements.
2Weight of stationary object
If hollow glass spheres are incorporated in the matrix, then specific weight is reduced to about 0.87 g/cm³, but thermal conductivity may be compromised
Solution Approach 1:
The patent uses local quality by positioning compact resin zones specifically adjacent to battery surfaces where heat generation occurs, while allowing foamed zones with hollow spheres in inner regions. This strategic placement ensures that critical heat transfer paths maintain high conductivity while non-critical regions utilize weight-reducing foamed structures.
Solution Approach 2:
The patent applies segmentation by dividing the matrix into distinct functional zones: compact outer zones for thermal management and foamed inner zones for weight reduction. This segmentation allows the matrix to simultaneously achieve both high thermal conductivity where needed and low specific weight where thermal demands are lower.
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 achieves a lower weight battery pack with thermal conductivity values comparable to traditional designs, ensuring efficient heat dissipation during charging, as demonstrated by the formation of compact layers and foamed structures that promote heat transfer.
Implementation Method 1
a synthetic resin matrix, having compact outer areas with high thermal conductivity, provided adjacent to or near the body of the batteries, i.e. the heat source
Implementation Method 2
inner foamed or expanded areas of lower weight than the outer ones
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A rechargeable battery pack, which has: - a thin compact layer or skin (9) of matrix (4) on the surfaces of contact of the latter with the outer walls (8a) of the batteries (2) and the inner walls (8b) of the container (3), which promotes the heat dissipation from the batteries to the outside of the battery pack (1); and - portions (10) of foamed or expanded matrix (4), which fill the empty spaces between the batteries and the walls of the container and which are suitable for reducing the total weight of the battery pack (1) compared with a compact non-foamed matrix. In comparison with the prior art embodiments, the invention allows a rechargeable battery pack to be produced that combines a lower weight with the thermal conductivity values required to dispose of the heat generated in the battery recharge phase.