Composite Sheet with Sealed Through Holes for Battery Pack Thermal Management
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Solution Overview
Problem
Conventional composite sheets used for heat dissipation in electronic equipment often cause air bubbles when adhered to devices, leading to reduced thermal conduction and potential mechanical failures due to expanding air bubbles and pressure on the device.
Innovation Solution
A composite sheet design featuring a thermally-conductive sheet sandwiched between two insulating sheets, with the insulating sheets sealing the thermally-conductive sheet's through holes to prevent air bubble formation, utilizing a smaller second through hole to exhaust air and maintain effective thermal conduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional composite sheets are adhered to target devices, then thermal conduction is achieved, but air bubbles form causing reduced thermal conduction and potential mechanical failures
Solution Approach 1:
The patent applies preliminary action by pre-forming through holes in the insulating sheets before the adhesion process. These through holes are positioned to align with air trapped during adhesion, allowing air to escape during the bonding process rather than forming bubbles that would compromise thermal conduction. This preventive measure eliminates the harmful effect of air bubbles before they can cause thermal conduction failure.
2Object-affected harmful factors
If through holes are provided in thermally-conductive sheets for air exhaust, then air bubble formation is reduced, but thermal conduction performance deteriorates due to holes in the heat dissipation path
Solution Approach 1:
The patent applies local quality by providing thermal conduction ribs that surround the through holes in the thermally-conductive sheet. These ribs are thermally conductive structures that locally compensate for the heat conduction loss caused by the through holes. The ribs create a thermal bridge that maintains heat flow paths around the holes, thus preserving overall thermal conduction performance while allowing the holes to function for air exhaust.
Solution Approach 2:
The patent uses composite materials by combining thermally-conductive materials with insulating materials in a multi-layer structure. The thermally-conductive sheet provides the primary heat dissipation function, while the insulating sheets with through holes provide air exhaust capability. The composite structure allows both functions to coexist without significantly compromising thermal conduction, as the insulating sheets are positioned to minimize thermal resistance while enabling air escape through the aligned holes.
3Object-affected harmful factors
If insulating sheets cover the thermally-conductive sheet to prevent air bubbles, then air bubble formation is suppressed, but thermal conduction efficiency decreases due to insulating material between heat paths
Solution Approach 1:
The patent uses thermal conduction ribs as intermediaries between the insulating sheets and the thermally-conductive sheet. These ribs are made of thermally conductive material and are positioned at the interfaces where insulating sheets meet the thermally-conductive sheet. They act as thermal bridges that bypass the insulating material, maintaining efficient heat conduction paths while allowing the insulating sheets to prevent air bubble formation in the adhesion interface.
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 design effectively suppresses air bubble formation and enhances thermal conduction properties, preventing thermal and mechanical failures by ensuring a bubble-free interface between the composite sheet and the external device, particularly effective in large contact areas.
Implementation Method 1
thermally-conductive members such as the graphite sheets or the like have become used to dissipate the generated heat
Implementation Method 2
a first insulating sheet that covers one surface of the thermally-conductive sheet, and a second insulating sheet that covers another surface of the thermally-conductive sheet and seals the thermally-conductive sheet between the first and second insulating sheets
Data Source
AI summary
A composite sheet includes a thermally-conductive sheet, a first insulating sheet that covers one surface of the thermally-conductive sheet, and a second insulating sheet that covers another surface of the thermally-conductive sheet, and seals the thermally-conductive sheet between the first and second insulating sheets. The thermally-conductive sheet has a first through hole provided therein. The composite sheet has an insulating lamination portion at which the first insulating sheet is stacked on the second insulating sheet to seal an inner wall surface of the first through hole. The insulating lamination portion has a second through hole provided inside the first through hole and having a hole diameter which is smaller than a hole diameter of the first through hole.