Double-Layer TIM Structure for Gap-Free Battery Cell Cooling
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Solution Overview
Problem
Conventional battery pack manufacturing involves complex procedures and errors in embedding heat conductive rods, leading to inefficient heat dissipation and potential manufacturing failures.
Innovation Solution
A double-layered thermal interface material structure with a supporting mesh plate and concave portions is sandwiched between battery cells, providing improved softness, malleability, and support, allowing for easier assembly and enhanced heat dissipation by distributing thermal conductive fillers across the gaps between cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heat conductive rods and conductive fillers are used to fill gaps between battery cells, then heat dissipation efficiency is improved, but manufacturing complexity increases and manufacturing precision deteriorates
Solution Approach 1:
The patent combines heat conductive rods and conductive fillers into a single integrated thermal interface material layer. This layer includes a mesh substrate with heat conductive rods embedded in the planes of the mesh substrate, and conductive fillers filling gaps between adjacent rods. The merging eliminates the need for separate placement operations, reducing manufacturing complexity while maintaining heat dissipation efficiency.
Solution Approach 2:
The heat conductive rods are pre-embedded into the mesh substrate during material fabrication, creating a pre-assembled thermal interface material. This preliminary action eliminates the need for separate rod placement operations during battery pack assembly, reducing manufacturing steps and improving precision by eliminating alignment errors.
2Temperature
If heat conductive rods are embedded into spacing regions between battery cells, then heat dissipation is improved, but manufacturing precision deteriorates due to embedding errors
Solution Approach 1:
The heat conductive rods are pre-embedded into the mesh substrate during material fabrication, creating a pre-assembled thermal interface material. This preliminary action eliminates the need for separate rod placement operations during battery pack assembly, reducing manufacturing steps and improving precision by eliminating alignment errors.
Solution Approach 2:
The mesh substrate provides a structured porous framework with predetermined spacing regions. The heat conductive rods are embedded within this pre-formed porous structure, ensuring precise positioning without requiring high-precision placement operations. The conductive fillers further fill remaining gaps, ensuring complete thermal contact.
3Temperature
If multiple heat conductive rods are disposed into spacing regions, then heat dissipation efficiency is improved, but manufacturing time increases
Solution Approach 1:
The patent combines heat conductive rods and conductive fillers into a single integrated thermal interface material layer. This layer includes a mesh substrate with heat conductive rods embedded in the planes of the mesh substrate, and conductive fillers filling gaps between adjacent rods. The merging eliminates the need for separate placement operations, reducing manufacturing complexity while maintaining heat dissipation efficiency.
Solution Approach 2:
The heat conductive rods are pre-embedded into the mesh substrate during material fabrication, creating a pre-assembled thermal interface material. This preliminary action eliminates the need for separate rod placement operations during battery pack assembly, reducing manufacturing steps and improving precision by eliminating alignment errors.
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 simplifies the assembly process, reduces manufacturing errors, and enhances heat dissipation efficiency by ensuring consistent embedding of thermal interface materials between battery cells, thereby improving the overall performance of battery modules and packs.
Implementation Method 1
a layer structure, made of a thermal interface material... the double-layered TIM structure is sandwiched between two adjacent rows of the battery cells... enhanced heat dissipation by ensuring consistent embedding of thermal interface materials between battery cells
Data Source
AI summary
A double-layered thermal interface material (TIM) structure is disclosed. The double-layered TIM structure is adopted for being sandwiched between each two adjacentN rows of battery cells of a battery module. According to the present invention, the double-layered TIM structure comprises a layer structure comprising a top surface and a bottom surface, of which the top surface and the bottom surface both have a plurality of concave portions. Moreover, there is a supporting mesh plate buried in the layer structure for making the layer structure simultaneously possess advantages of softness, good malleability and good support capability. Therefore, when this novel double-layered TIM structure is adopted in assembling N rows of battery cells to become a battery module, there are no interfacial gaps between the two adjacent rows of battery cells and the double-layered TIM structure.