Battery Pack Support Frame With Vents And Heat Sink
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Solution Overview
Problem
Battery packs used in harsh environments, such as construction sites, often suffer from damage and reduced operational lifespan due to inadequate support and poor heat dissipation, as closely packed cells lack sufficient space for heat radiation and air flow.
Innovation Solution
A battery pack design featuring a support frame with recesses and vents that space apart battery cells, providing individual support and maximizing airflow, while incorporating a heat sink to isolate and efficiently dissipate heat through passive air flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery cells are fastened closely together to prevent damage and dislodgement, then reliability is improved, but heat dissipation deteriorates
Solution Approach 1:
The battery pack is divided into modular sections with individual cell holders that secure each cell separately. This segmentation allows cells to be firmly positioned (improving reliability) while maintaining spacing between them for heat dissipation (addressing the temperature issue).
Solution Approach 2:
Different regions of the battery pack have different cell spacing configurations. Peripheral cells have greater spacing for heat dissipation, while central cells are more tightly packed. This local variation in spacing quality allows simultaneous achievement of stability and thermal management.
2Reliability
If a tight bunching of cells is used to prevent damage, then reliability is improved, but air flow and heat radiation are reduced
Solution Approach 1:
The battery pack structure segments cells into individually supported positions within holders, preventing the tight bunching that causes heat accumulation while maintaining cell protection through structured arrangement and securing mechanisms.
3Device complexity
If passive cooling is used without forced air flow, then device complexity is reduced, but heat dissipation capability deteriorates
Solution Approach 1:
The patent transitions from relying solely on natural convection (one-dimensional heat transfer) to incorporating forced air flow through channels (adding dimensional complexity to airflow paths). This enables significantly enhanced heat dissipation capability while maintaining reasonable device complexity through integrated cooling channels rather than separate active cooling systems.
4Temperature
If cells are spaced apart to maximize air flow, then heat dissipation is improved, but cell stability and support deteriorate
Solution Approach 1:
The battery pack uses segmented cell holders that provide individual support positions for each cell. This segmentation allows cells to be spaced apart for heat dissipation while each cell remains securely positioned in its designated holder, preventing instability.
Solution Approach 2:
Cell holders act as intermediary structures between the cells and the battery pack housing. These holders provide the necessary support and positioning (ensuring stability) while allowing optimized spacing between cells for air flow and heat dissipation (improving temperature management).
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 effectively prevents overheating and enhances the long-term performance of battery packs by ensuring proper airflow and heat dissipation, even in harsh conditions, thereby extending the battery pack's operational life.
Implementation Method 1
maximize air flow around and over each of the battery cells
Implementation Method 2
incorporating a heat sink to isolate and efficiently dissipate heat through passive air flow
Data Source
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AI summary
There is a battery pack, the battery pack comprising: an upper housing portion including a first air vent; and a lower support frame configured to receive a plurality of battery cells and to space apart the battery cells from one another. The lower support frame includes a second air vent positioned at a first end of the lower support frame, a third air vent positioned at a second end of the lower support frame and opposite the second air vent, and an air passage positioned between the second air vent and the third air vent. The first air vent is above the second air vent, and the second air vent is at least partially isolated from the first air vent by a heat sink.