Battery Pack PCB Layout for Heat Dissipation and Temperature Sensing

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Solution Overview

Problem

Conventional battery packs face challenges in thermal management and size reduction due to non-thermally conductive PCBs, which can lead to overheating and inadequate temperature detection.

Innovation Solution

The battery pack design incorporates a first PCB with an aluminum base layer and an intermediate layer having sections of different thermal conductivities, positioned between the battery cells and the PCB, along with a second PCB mounted opposite the first, to enhance thermal insulation and conduction, and includes thermistors for accurate temperature measurement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a non-thermally conductive PCB is used, then the PCB provides electrical insulation, but thermal management is inadequate leading to overheating

Engineering Contradiction:

Improvethermal managementVSAvoidoverheating

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The PCB is segmented into multiple layers with different thermal properties. The first PCB layer includes a metal base layer (aluminum) for thermal conduction, while the second PCB layer provides electrical insulation. This segmentation allows simultaneous achievement of thermal management and electrical insulation functions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The first PCB uses a composite structure combining a metal base layer (aluminum with high thermal conductivity of 237 W/m·K) with a non-conductive substrate layer. This composite material approach enables the PCB to conduct heat effectively while maintaining electrical insulation properties.

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If thermal insulation is added between battery cells and PCB, then overheating is prevented, but temperature detection accuracy decreases

Engineering Contradiction:

Improveoverheating preventionVSAvoidtemperature detection

Core Design Contradiction:

Object-affected harmful factorsVSMeasurement precision

Solution Approach 1:

The intermediate layer between battery cells and PCB has non-uniform thermal conductivity. It includes a first section with lower thermal conductivity (0.2-2.0 W/m·K) for thermal insulation and a second section with higher thermal conductivity (10-50 W/m·K) for temperature detection. This local quality variation allows simultaneous thermal protection and accurate temperature monitoring.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The intermediate layer acts as a mediator between the battery cells and PCB. It provides thermal insulation to prevent overheating while containing thermistors that serve as intermediaries for temperature detection, enabling both protective and sensing functions.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Volume of stationary object

If PCB size is reduced to shrink battery pack, then battery pack size decreases, but thermal dissipation capability is reduced

Engineering Contradiction:

Improvebattery pack sizeVSAvoidheat dissipation

Core Design Contradiction:

Volume of stationary objectVSLoss of energy

Solution Approach 1:

The first PCB employs a metal base layer (aluminum) with high thermal conductivity (237 W/m·K) combined with a non-conductive substrate. This composite structure provides effective thermal dissipation capability in a compact form factor, enabling reduced battery pack size without sacrificing thermal management performance.

Inventive Principle:

Principle #40Composite materials

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 design effectively dissipates heat, reduces the size of the battery pack, and ensures accurate temperature detection, addressing overheating issues and improving thermal management.

Implementation Method 1

The first PCB includes an aluminum base layer

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

The intermediate layer includes a first section formed of a first material and a second section formed of a second material. The first material has a lower thermal conductivity than the second material.

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 3

The battery pack includes thermistors for accurate temperature measurement

Methodology Applied

Scientific EffectThermistor effect: Thermistor

Data Source

PatentUS20230411801A1Battery pack

Publication Date: 2023.12.21 MILWAUKEE ELECTRIC TOOL CORP

AI summary

A battery pack is configured to be coupled to an electrical device. The battery pack includes a battery cell; a printed circuit board (PCB) having a metal base layer; and an intermediate layer positioned between the battery cell and the PCB, the intermediate layer including a first section formed of a first material and a second section formed of a second material, the first material having a lower thermal conductivity than the second material.