Flat Heat Pipe Battery Pack Cooling via Vapor Chamber
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Solution Overview
Problem
High-density, small form-factor battery cells in battery packs face challenges in maintaining a constant temperature due to heat generation, leading to degradation, and conventional cooling systems are prone to liquid leakage and electrical shorts.
Innovation Solution
The use of heat pipes with thermal interface materials for efficient heat transfer and a unified cooling system that maintains even temperature across cells, reducing the risk of liquid leakage by minimizing direct contact between circulating liquid and cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional circulating-liquid manifolds are used for cooling, then cooling capability is provided, but liquid leakage may short electrical connections and damage system components
Solution Approach 1:
The patent introduces a vapor chamber as an intermediary heat transfer device between the battery cells and the cooling liquid. The vapor chamber absorbs heat from the battery cells through phase change of the working fluid inside, then transfers this heat to the cooling liquid through its external surface. This mediator eliminates direct contact between the cooling liquid and electrical components, preventing liquid leakage from causing electrical shorts while maintaining effective cooling.
2Area of stationary object
If small form-factor battery cells are used, then surface-area-to-volume ratio increases for better cooling potential, but heat generation in high cell-count packs creates temperature management challenges
Solution Approach 1:
The patent merges multiple small battery cells into a unified thermal management system using a single vapor chamber that covers the entire battery pack surface. Instead of providing individual cooling for each cell, the vapor chamber creates a unified thermal field that distributes heat evenly across all cells through phase change heat transfer, maintaining temperature uniformity despite the high cell count and increased heat generation.
3Duration of action of stationary object
If battery cells are cooled to prevent degradation, then cell life is extended, but maintaining constant temperature across all cells is a substantial challenge
Solution Approach 1:
The patent changes the thermal management approach from active temperature control (pumps, valves, complex flow distribution) to passive phase change heat transfer. The vapor chamber utilizes the phase change parameters of the working fluid (evaporation at constant temperature, condensation releasing heat) to automatically maintain uniform temperature across all battery cells without complex control systems, thereby extending cell life while simplifying the device complexity.
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 approach effectively manages heat distribution across the battery pack, maintaining cell performance and reducing the risk of electrical failures and liquid leakage, thereby extending the life and reliability of the battery cells.
Implementation Method 1
A method for cooling a battery cell comprising: positioning a heat pipe on a side of the battery cell
Implementation Method 2
The heat pipe comprises a capillary structure and a working fluid disposed within the capillary structure
Implementation Method 3
positioning a heat pipe on a side of the battery cell; positioning a thermal interface material between the battery cell and the heat pipe
Data Source
AI summary
Methods of cooling a battery pack comprising a large number of cells are disclosed in various embodiments. In one embodiment, one or more low thermal resistance heat pipes are used to transfer heat away from the battery pack. In another embodiment, the heat pipes are coupled to a cold plate cooled by circulating liquid.