Gradient Thermal Composite for Fast-Charging Energy Pack Cooling
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Solution Overview
Problem
Existing passive cooling techniques are insufficient to provide adequate thermal regulation for energy packs during fast charging, leading to safety and reliability issues due to high temperatures, especially in mobile robotics applications where space and energy efficiency are critical.
Innovation Solution
A thermal conductive composite with a gradient structure, comprising a thermal conductive material and a phase change material, is used to create a non-uniform heat absorption profile, transferring heat energy away from the heat source to an area with a large latent heat absorbing capacity, thereby reducing overall maximum temperature and preventing shape deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If active cooling techniques are used, then cooling effectiveness is improved, but device complexity and energy consumption increase
Solution Approach 1:
The patent replaces active mechanical cooling systems (blowers, pumps) with a passive thermal conductive composite structure that uses inherent material properties (thermal conductivity gradient and phase change) to achieve cooling without moving parts or external energy input
Solution Approach 2:
The thermal conductive composite structure autonomously performs cooling functions by utilizing the temperature difference between the heat source and environment, combined with phase change material absorption, eliminating the need for external power or control systems
2Temperature
If active cooling techniques are used, then cooling effectiveness is improved, but use of energy increases
Solution Approach 1:
The patent replaces active mechanical cooling systems (blowers, pumps) with a passive thermal conductive composite structure that uses inherent material properties (thermal conductivity gradient and phase change) to achieve cooling without moving parts or external energy input
3Ease of manufacture
If uniform porous structure is used, then heat absorption is simplified, but cooling efficiency decreases
Solution Approach 1:
The patent applies different porosity values at different locations within the thermal conductive composite structure, with higher porosity regions positioned to optimize heat absorption and phase change material distribution, creating localized functional zones that enhance overall cooling efficiency
4Productivity
If fast charging is implemented, then productivity is improved, but temperature increases causing safety issues
Solution Approach 1:
The patent incorporates phase change materials within the thermal conductive composite structure that absorb excess heat generated during fast charging by transitioning between solid and liquid phases, maintaining battery temperature within safe operating limits while enabling high charging rates
Solution Approach 2:
The patent uses a composite structure combining thermal conductive materials with phase change materials in a gradient porous configuration, creating a multi-functional material system that simultaneously conducts heat away from the battery and absorbs thermal energy through phase change
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 enables efficient cooling of energy packs, allowing for fast charging without safety risks, as it effectively reduces maximum temperatures and maintains battery performance and safety, even at high charging rates.
Implementation Method 1
A thermal conductive composite with a gradient structure, comprising a thermal conductive material and a phase change material, is used to create a non-uniform heat absorption profile, transferring heat energy away from the heat source to an area with a large latent heat absorbing capacity
Implementation Method 2
transferring heat energy away from the heat source to an area with a large latent heat absorbing capacity, thereby reducing overall maximum temperature
Implementation Method 3
A thermal conductive composite with a gradient structure, comprising a thermal conductive material and a phase change material, is used to create a non-uniform heat absorption profile, transferring heat energy away from the heat source
Data Source
AI summary
Systems and methods in which a thermal conductive composite comprises a non-uniform heat absorption profile of a thermal reactive material are described. Thermal conductive composites herein may be utilized in thermal regulatory modules with a gradient structure configured to transfer heat energy away from an area near a heat source to an area with a relatively large latent heat absorbing capacity. Thermal conductive material may be provided in a frame structure having lower porosity in a first region more near a heat source and higher porosity in a second region more distant from the heat source. A thermal reactive material may be deposited so as to be disposed within the pores of the thermal conductive material frame structure wherein the density of the thermal reactive material in the first region of the thermal conductive composite is lower than that at the second region of the thermal conductive composite.