Battery Pack PCM Bladder Thermal Management
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Solution Overview
Problem
Battery packs face premature disablement and reduced operational life due to excessive heat generation during high amperage discharges, leading to incomplete energy discharge and interrupted power supply to tools or devices.
Innovation Solution
Incorporation of phase change material within the battery pack housing that contacts the battery cells and a heat sink for effective heat management, delaying high temperature conditions and allowing complete discharge before disabling the pack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If battery cells operate during high amperage discharge, then power output is improved, but temperature increases causing cell damage and premature disablement
Solution Approach 1:
The patent utilizes phase change material that transitions between solid and liquid states at a specific temperature threshold. During high amperage discharge, when battery cells generate excessive heat, the phase change material absorbs the excess thermal energy by transitioning from solid to liquid phase, thereby maintaining cell temperature within safe operating limits while allowing continuous high-power operation
Solution Approach 2:
The phase change material acts as an intermediary thermal management component positioned between the battery cells and the surrounding environment. It mediates heat transfer by absorbing excess heat from the cells during high-power operation and releasing it during low-power operation, enabling the cells to operate at higher power levels without temperature-related damage
2Reliability
If temperature management components disable cells exceeding maximum temperature threshold, then cell damage is minimized, but power supply is interrupted
Solution Approach 1:
The phase change material is positioned in direct thermal contact with the battery cells before high-temperature conditions occur. It proactively absorbs excess heat as it begins to generate, preventing the temperature from reaching the disablement threshold in the first place, thereby maintaining continuous power supply while protecting the cells
Solution Approach 2:
The invention converts the harmful excess heat that would normally cause cell damage and trigger disablement into a beneficial thermal management mechanism. The phase change material absorbs the harmful heat energy during its phase transition, transforming what would be a dangerous condition into a controlled thermal regulation process that allows continuous operation
3Temperature
If phase change material encapsulates battery cells, then heat absorption is improved, but cell access and maintenance difficulty increases
Solution Approach 1:
The patent employs a flexible bladder or membrane to encapsulate the phase change material and position it against the battery cells. This flexible enclosure maintains intimate thermal contact for effective heat absorption while allowing the battery cells to be accessed by simply removing or deflating the bladder, thus preserving ease of maintenance and manufacturing
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 phase change material absorbs excess heat, minimizing cell damage, extending battery life, and enabling continuous power supply until complete discharge, even during high load applications.
Implementation Method 1
phase change material within the housing and at least partially encapsulating the cell, the phase change material contacting the cell through the opening
Implementation Method 2
The phase change material absorbs excess heat, minimizing cell damage, extending battery life
Implementation Method 3
The battery pack may include a heat sink in heat transfer relationship with the phase change material, the heat sink extending to an exterior of the housing
Data Source
AI summary
A bladder configured to support a phase change material in a heat transfer relationship with at least one battery cell including a wall defining a channel, the phase change material surrounding a portion of the channel.