Battery Pack Thermally Conductive Resin Layer Heat Dissipation
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Solution Overview
Problem
Lithium secondary batteries in battery packs face challenges with heat dissipation due to complex structures and air gaps, leading to performance deterioration, shortened life, and increased risk of explosion or ignition, especially in high-temperature conditions, while also requiring improved cooling, downsizing, and increased capacity.
Innovation Solution
A battery pack design featuring a thermally conductive resin layer between the module and pack frames, with open portions on the module frame to directly contact the cell stack, and an optional heat sink, reducing the need for additional heat transfer members and simplifying the structure for enhanced cooling performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a battery module with a plurality of battery cells is stacked to improve capacity and output, then high output is obtained, but heat generated from the battery cells during charging and discharging is difficult to remove
Solution Approach 1:
The patent extracts the heat transfer function from the complex multi-layer structure and concentrates it into a single thermally conductive adhesive layer positioned directly between the battery cell and heat sink. This eliminates intermediate air gaps and structural barriers, allowing heat to be extracted more efficiently from the battery cell during high-power operation.
Solution Approach 2:
The patent creates an asymmetric thermal path by forming a protrusion on the battery cell that directly contacts the heat transfer member, while the rest of the cell surface maintains its original structure. This asymmetric contact design ensures optimal thermal coupling at the hottest spots without compromising the overall cell structure or electrical performance.
2Temperature
If thermal pads or heat sinks are used as cooling means, then cooling performance is improved, but the complicated structure connected to battery cell and battery module creates air gaps that disturb cooling performance
Solution Approach 1:
The patent merges the heat transfer function with the existing structural components by integrating a heat transfer member into the battery module assembly. The thermally conductive adhesive serves dual purposes: it bonds the heat sink to the battery cell while simultaneously providing the thermal conduction path, eliminating the need for separate thermal interface materials and reducing structural complexity.
Solution Approach 2:
The patent introduces a thermally conductive adhesive as an intermediary substance between the battery cell and heat sink. This adhesive mediator fills microscopic air gaps and surface irregularities, ensuring optimal thermal contact while maintaining mechanical bonding, thus resolving the conflict between structural integrity and thermal performance.
3Temperature
If additional heat transfer members are added to improve cooling, then heat dissipation is enhanced, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent designs the heat transfer member to perform multiple functions simultaneously: it serves as a thermal conduction path, a mechanical bonding agent, and a structural support element. This multi-functionality eliminates the need for separate components for each function, reducing the total number of parts while maintaining effective heat dissipation.
Solution Approach 2:
The patent employs composite material structures where the heat transfer member combines materials with different properties - high thermal conductivity for heat dissipation, adhesive properties for bonding, and mechanical strength for structural support. This composite approach allows a single component to replace multiple specialized parts.
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 improves cooling efficiency, reduces costs, and increases capacity and output by simplifying the structure, reducing air gaps, and allowing for more compact and effective heat transfer, while ensuring safety and stability.
Implementation Method 1
a thermally conductive resin layer located between a lower surface of the module frame and the pack frame
Data Source
AI summary
A battery pack according to an embodiment of the present disclosure includes a battery module having a cell stack in which one or more battery cells are stacked and a module frame for accommodating the cell stack therein; a pack frame accommodating the battery module therein; and a thermally conductive resin layer located between a lower surface of the module frame and the pack frame. An open portion is formed on the lower surface of the module frame, so that the cell stack is in contact with the thermally conductive resin layer.