Ceramic-Filled Thermoplastic Battery Housing for Thermal Management
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Solution Overview
Problem
Electric cycles with battery-powered propulsion systems face challenges in effectively managing heat dissipation and electrical insulation, leading to potential temperature-related issues and inefficiencies in battery performance.
Innovation Solution
A housing made from a thermoplastic resin with added ceramic materials, designed to conduct heat while insulating against electrical conduction, is used to encase the battery pack, providing a thermally conductive and electrically insulating solution that includes cooling fins for enhanced heat transfer and a hermetically sealed structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a traditional plastic housing is used for the battery pack, then electrical insulation is provided, but heat dissipation is insufficient leading to high operating temperatures
Solution Approach 1:
The housing is constructed from a composite material consisting of thermoplastic resin and ceramic particles. The ceramic provides high thermal conductivity for heat dissipation while the thermoplastic resin matrix provides electrical insulation. This composite structure resolves the contradiction by simultaneously achieving both thermal conduction and electrical insulation in a single integrated housing component.
2Temperature
If thermally conductive materials are used for the housing, then heat dissipation improves, but electrical insulation may be compromised
Solution Approach 1:
The composite housing combines ceramic particles (thermally conductive) embedded in a thermoplastic resin matrix (electrically insulating). This allows the housing to conduct heat effectively through the ceramic network while maintaining electrical insulation through the resin matrix, thus resolving the contradiction between thermal conduction and electrical insulation requirements.
3Temperature
If more battery cells are used to maintain performance at lower temperatures, then temperature control improves, but device complexity increases
Solution Approach 1:
The housing itself serves as an active heat dissipation component through its thermally conductive ceramic-filled structure, eliminating the need for additional complex cooling systems or temperature management components. The housing performs both structural support and thermal management functions, reducing overall device complexity while maintaining temperature control.
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 solution effectively reduces operating temperatures of the battery pack, allowing for a potentially reduced number of battery cells while maintaining performance, and ensures protection against environmental factors like dust and water.
Implementation Method 1
The housing may comprise a plastic that has a first thermal conductivity. The housing may contain an additive that is electrically insulating and that has a second thermal conductivity that is greater than the first thermal conductivity.
Implementation Method 2
The housing may contain an additive that is electrically insulating and that has a second thermal conductivity that is greater than the first thermal conductivity.
Implementation Method 3
The external surface may have cooling fins
Implementation Method 4
The external surface may have cooling fins
Data Source
AI summary
A product may include a battery pack, and a housing may receive the battery pack. The housing may comprise a plastic containing an additive that is electrically insulating and that has a greater thermal conductivity than the plastic.