Graphite-PCM Moldable Mass for Battery Thermal Management
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Solution Overview
Problem
Existing solutions for temperature management in battery packs, particularly lithium-ion batteries, face challenges in efficiently absorbing and dissipating heat due to low thermal conductivity of phase change materials and the complexity and cost of producing form-fitting cooling structures.
Innovation Solution
A moldable mass composed of graphite and phase change material, incorporating binders and microcapsules, which can be shaped into complex forms for a positive fit with battery packs, offering improved thermal conductivity and mechanical strength while allowing for efficient heat storage and discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If phase change material (PCM) is used as embedding material in battery arrangement, then thermal storage capacity is improved, but thermal conductivity deteriorates
Solution Approach 1:
The patent combines phase change material (PCM) with graphite particles to create a composite thermal management material. The graphite provides high thermal conductivity while the PCM provides thermal storage capacity through phase transition, resolving the contradiction between these two properties.
Solution Approach 2:
The patent creates regions with different material properties by distributing graphite particles within the PCM matrix. The graphite-rich regions provide thermal conduction pathways while PCM-rich regions provide thermal storage, allowing local optimization of both properties.
2Reliability
If stable packaging is used to encase graphite-PCM mixture, then leakage prevention is improved, but manufacturing complexity deteriorates
Solution Approach 1:
The patent uses a flexible polymer matrix to encapsulate the graphite-PCM mixture, replacing rigid stable packaging. This flexible encapsulation prevents leakage while allowing the material to be molded into complex shapes that fit battery packs, reducing manufacturing complexity.
Solution Approach 2:
The patent changes the physical state of the packaging from rigid to flexible by using a polymer matrix that can be molded. This allows the packaging to adapt to different battery pack geometries, simplifying manufacturing while maintaining leakage prevention.
3Stability of the object's composition
If rigid packaging is used for battery arrangement, then structural stability is improved, but adaptability to different battery pack shapes deteriorates
Solution Approach 1:
The patent transitions from rigid to flexible packaging structure that can adapt its shape. The flexible polymer matrix allows the thermal management component to conform to different battery pack geometries while maintaining structural integrity through the graphite-PCM composite network.
Solution Approach 2:
The flexible polymer encapsulation allows the thermal management material to be molded into various shapes that fit different battery pack configurations, providing both structural stability and shape adaptability.
4Manufacturing precision
If complex shapes are produced with conventional processes, then manufacturing precision is improved, but production cost deteriorates
Solution Approach 1:
The patent utilizes the moldability of the flexible polymer-PCM-graphite composite to produce complex shapes through conventional molding processes. By adjusting processing parameters such as temperature and pressure, precise complex geometries can be achieved cost-effectively.
Solution Approach 2:
The patent incorporates the final shape requirements into the molding process itself, creating the complex battery-fitting geometry during initial production. This preliminary shaping eliminates the need for subsequent complex machining or assembly operations, reducing costs while maintaining precision.
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 solution enables the production of lightweight, complex structures with enhanced thermal conductivity and mechanical stability, effectively managing temperature fluctuations in battery packs and other applications, ensuring reliable operation across varying temperatures.
Implementation Method 1
absorb excess heat in the form of latently stored heat when an excessive thermal budget occurs through phase conversion of the PCM
Implementation Method 2
absorb excess heat in the form of latently stored heat when an excessive thermal budget occurs through phase conversion of the PCM
Implementation Method 3
the specific thermal conductivity of the proposed PCMs is very low, so the loading and unloading dynamics are very low and not sufficient for a technical application
Data Source
AI summary
The invention relates to a moldable mass comprising graphite and phase change material, comprising graphite and phase change material (PCM), characterized in that it comprises binder and microcapsules comprising the PCM, to a process for producing a molding from this mass, and to a molding and the use thereof.