Modular Sealed Battery Pack Housing for Passive Heat Dissipation
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Solution Overview
Problem
Existing battery packs face challenges in efficiently dissipating heat while maintaining safety, particularly in high-energy density applications, leading to potential explosions and hazardous conditions, and existing solutions increase volume, cost, or require additional energy consumption.
Innovation Solution
A modular battery pack system with a thermally conductive structural housing element, a vent assembly for gas exchange, and a lid element for mechanical strength and electrical coupling, integrated with a circuit for monitoring and controlling battery operations, including a PCB for data transfer and safety features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high energy density battery cells are used to increase capacity and output power, then battery performance is improved, but heat generation increases and safety risks increase
Solution Approach 1:
The patent converts the harmful heat generated by high-energy-density battery cells into a beneficial feature by using the battery pack housing itself as a heat sink. The housing is designed with thermally conductive material and specific geometric features (fins, channels, or integrated cooling structures) that actively dissipate heat from the battery cells, transforming the heat problem into a controlled thermal management system that maintains safety while preserving high power output capability
Solution Approach 2:
The housing structure serves multiple functions simultaneously: it provides mechanical support and containment for the battery cells, acts as a thermal management system through integrated heat dissipation features, and serves as a structural component of the battery pack. This multi-functionality eliminates the need for separate cooling components, reducing overall pack volume while maintaining effective heat dissipation
2Temperature
If forced air cooling systems with fans are used to dissipate heat, then heat dissipation is improved, but device volume increases and manufacturing cost increases
Solution Approach 1:
The patent extracts the active cooling mechanism (fan) from the battery pack system and replaces it with passive thermal management features integrated into the housing structure. The housing incorporates thermally conductive pathways, fins, and channels that naturally dissipate heat without requiring mechanical cooling components, thereby reducing pack volume while maintaining effective temperature control
Solution Approach 2:
The battery pack housing performs thermal management functions autonomously through its inherent structural design. The thermally conductive housing material and integrated cooling features (fins, channels) automatically dissipate heat from the battery cells based on thermal gradients, without requiring external control systems or additional energy input, making the system self-regulating
3Temperature
If unsealed battery packs with safety valves are used to release pressure, then heat release is improved, but safety in moist environments deteriorates
Solution Approach 1:
The patent employs a sealed housing structure with integrated pressure relief mechanisms that maintain environmental protection while allowing controlled pressure release. The housing acts as a flexible barrier that can withstand pressure buildup and selectively release gases through controlled pathways, preventing moisture ingress while managing thermal and pressure effects from battery operation
4Temperature
If temperature feedback shut-off control is used to regulate internal temperature, then temperature regulation is improved, but power requirements increase
Solution Approach 1:
The battery pack housing performs thermal management functions autonomously through its inherent structural design. The thermally conductive housing material and integrated cooling features (fins, channels) automatically dissipate heat from the battery cells based on thermal gradients, without requiring external control systems or additional energy input, making the system self-regulating
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 system effectively manages heat dissipation and safety, preventing adverse events like explosions while maintaining compact size and reducing manufacturing costs, with integrated monitoring and control capabilities.
Implementation Method 1
a thermally conductive structural housing element configured to house a battery assembly in an interior volume
Implementation Method 2
The lid element and/or the thermally structured housing element may include a vent assembly for allowing exchange of gases to and from the interior volume while restricting entry of water into the interior volume
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
Modular sealed battery packs configured to provide enhanced performance and safety features, along with associated apparatus, systems, and methods for monitoring and controlling operation and use of such battery packs and associated systems are disclosed.