Battery Pack Mounting and Cooling via Rigid Substrates
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Solution Overview
Problem
Conventional battery systems face issues with physical stability, mechanical strength, heat management, and manufacturing complexity when using multiple batteries in series or parallel configurations, particularly in vibration-prone environments, leading to potential short circuits, thermal runaway, and inefficient space utilization.
Innovation Solution
A battery system comprising a plurality of batteries sandwiched between two rigid substrates with through-holes for secure mounting and conductive connections, utilizing thermally conductive cooling tubes with liquid coolant to manage heat and prevent short circuits, and air cooling to maintain even temperatures, while allowing for flexible configuration to fit available space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If batteries are connected in series or parallel to obtain higher current and voltage, then power output is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple batteries into a single integrated battery pack assembly with unified housing, common cooling system, and integrated electrical connections. This merging approach achieves the desired power output through series/parallel configuration while reducing overall device complexity by eliminating the need for separate mounting and connection operations for individual batteries.
Solution Approach 2:
The battery pack housing serves multiple functions simultaneously: it provides mechanical support for all batteries, acts as the negative electrical terminal, incorporates cooling channels for thermal management, and provides structural protection. This multi-functionality reduces the number of separate components needed, thereby reducing device complexity while maintaining high power output capability.
2Power
If batteries are made larger to obtain higher current and voltage, then power output is improved, but heat retention increases
Solution Approach 1:
The patent divides the battery system into multiple individual battery cells arranged in series or parallel configuration. This segmentation increases the total surface area for heat dissipation compared to a single large battery, while achieving the same power output. Each battery maintains its own heat dissipation pathways, preventing heat accumulation.
Solution Approach 2:
The patent introduces a cooling system with cooling channels and coolant flow as an intermediary between the batteries and the environment. This cooling intermediary actively removes heat from the battery assembly, enabling high power output without excessive heat retention by facilitating efficient thermal transfer from the batteries to the coolant.
3Ease of manufacture
If conventional battery stacks are glued together to reduce assembly complexity, then manufacturing is simplified, but physical stability deteriorates
Solution Approach 1:
The patent incorporates pre-designed mounting features directly into the battery pack housing during manufacturing, such as recesses, clips, or interference-fit structures. These preliminary structural preparations ensure that when batteries are installed, they are automatically mechanically secured without requiring separate gluing operations, thereby maintaining both manufacturing simplicity and physical stability.
Solution Approach 2:
The patent replaces the chemical bonding mechanism (glue) with a mechanical fastening system integrated into the housing structure. This substitution uses physical features like recesses, clips, or interference fits to secure batteries, providing superior mechanical stability while maintaining ease of manufacture through tool-less or simple fastening mechanisms.
4Device complexity
If batteries are arranged in vibration-prone environments without additional protection, then device complexity is reduced, but reliability deteriorates
Solution Approach 1:
The patent integrates vibration protection features directly into the battery pack housing structure, combining mechanical support, vibration damping, and electrical connection functions into a unified design. This integration maintains structural simplicity while ensuring reliability in vibration-prone environments through built-in protective features.
Solution Approach 2:
The patent incorporates vibration-damping materials, flexible mounting elements, or shock-absorbing features into the housing design before the batteries are subjected to vibrational stresses. This beforehand cushioning protects the batteries and their connections from vibration-induced failures without adding complex external protection systems.
5Ease of manufacture
If conductors are pressed into battery cases during impact, then electrical connection is simplified, but short circuit risk increases
Solution Approach 1:
The patent introduces insulating barriers, protective sleeves, or isolated mounting structures as intermediaries between the conductors and the battery cases. These intermediary elements maintain simple electrical connections while preventing direct contact between conductors and the battery case during impacts, thereby eliminating short circuit risk.
Solution Approach 2:
The patent designs the housing and conductor mounting structures with built-in protection features that prevent conductors from being pressed into the battery case during impacts. This preliminary anti-action is built into the structure, such as through isolated mounting points, protective channels, or insulating barriers, that actively counteract the potential short circuit mechanism before it can occur.
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 enhances mechanical stability, prevents short circuits, maintains even temperatures, and reduces manufacturing complexity, enabling efficient use of space and reliable operation in vibration-prone environments.
Implementation Method 1
at least one thermally conductive cooling tube containing a liquid coolant, said at least one thermally conductive cooling tube positioned to be proximate a side portion of each of said plurality of batteries
Implementation Method 2
the cooling tube has a flow of said liquid coolant
Data Source
Figure 1~2B
Figure 3~4
Figure 5~6A
AI summary
A system and method mounts batteries in a substrate or insert to a substrate, electrically connects them via a set of conductors, and cools them using air, or cooling tubes having a flow of air or coolant running in opposite directions past each of the batteries.