Double-Sided Pouch Cell Cooling Assembly for Space-Efficient Heat Control
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Solution Overview
Problem
Existing battery pack cooling systems for electric aircraft do not effectively optimize temperature control while minimizing space usage, leading to suboptimal performance and reduced battery lifespan.
Innovation Solution
A double-sided battery pack cooling assembly is introduced, featuring a thermally insulating separator between two stacks of battery cells, with a cooling plate in contact with each stack and a temperature-sensing system monitored by a controller to manage heat transfer efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional single-sided cooling system is used, then the structure is simple, but the cooling efficiency is insufficient and battery temperature cannot be optimized
Solution Approach 1:
The battery pack is divided into two separate battery sections (first and second battery sections) with a thermally insulating separator between them. Each section has its own cooling plate contact surface, allowing independent temperature control and heat dissipation pathways. This segmentation enables more effective thermal management by treating different battery regions separately rather than as a single mass.
Solution Approach 2:
The cooling system transitions from single-sided cooling to double-sided cooling by adding cooling capability on both sides of the battery pack. The cooling plate contacts both the first battery section and the second battery section simultaneously, creating a three-dimensional thermal management structure that dissipates heat from multiple directions, thereby improving overall cooling efficiency.
2Reliability
If cooling space is increased to improve heat dissipation, then cooling efficiency improves, but the space occupied by the cooling system increases
Solution Approach 1:
The thermally insulating separator serves multiple functions simultaneously: it electrically isolates the two battery sections, provides a mounting surface for the cooling plate, and thermally separates the two battery sections while enabling heat dissipation. By merging these functions into a single component, the system achieves effective double-sided cooling without proportionally increasing the overall space occupied.
Solution Approach 2:
The cooling plate is designed to contact both battery sections and serve as a universal thermal management component. It simultaneously cools the first battery section through its first contact surface and the second battery section through its second contact surface, maximizing cooling efficiency within the available space without requiring separate cooling systems for each section.
3Reliability
If battery sections are separated to improve temperature control, then temperature management improves, but the device complexity increases
Solution Approach 1:
The battery pack is segmented into two distinct battery sections with a thermally insulating separator between them. Each section can be independently managed for temperature control, allowing for more precise thermal management. The segmentation is achieved through the insulating separator that physically and thermally divides the battery pack while maintaining structural integrity.
Solution Approach 2:
The thermally insulating separator acts as an intermediary component between the two battery sections. It provides electrical isolation, thermal separation, and structural support while enabling the cooling plate to contact both sections. This intermediary element facilitates temperature control without requiring complex wiring or additional cooling mechanisms.
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 configuration enhances temperature control, maximizes cooling efficiency, and minimizes space usage, thereby extending battery lifespan and improving the performance of electric aircraft.
Implementation Method 1
a first battery section separated from a second battery section by a thermally insulating separator
Implementation Method 2
a cooling plate having a first side and a second side, wherein the first side is in contact with the first stack of battery cells and the second side is in contact with the second stack of battery cells
Data Source
AI summary
A system for battery pack cooling including a battery pack. The battery pack includes a plurality of pouch cells and a separation element, where the separation separates at least a first pouch cell of the plurality pouch cells from a second pouch cell of the plurality of pouch cells. The separation element contains a fluid. The system also includes a cooling plate, where the cooling plate is adjacent to the lower side of the battery pack. The cooling plate comprises at least a cooling fin, where the at least a cooling fin extends towards the separation element.