Hollow Copper Ribbon Conductor for Battery Cell Cooling

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Solution Overview

Problem

Existing thermal management solutions for battery packs are inadequate in efficiently dissipating heat between closely packed battery cells, leading to potential thermal runaway and reduced battery performance.

Innovation Solution

A process to create a ribbon-shaped, hollow copper thermal conductor by forming a sacrificial insert with materials like metals, conductive polymers, or hard waxes, copper plating, and removing the sacrificial material to create a hollow passage, allowing for effective heat dissipation between battery cells.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional thermal management solutions are used for closely packed battery cells, then the structure is simple and easy to manufacture, but heat dissipation efficiency is insufficient leading to thermal runaway risk

Engineering Contradiction:

Improvethermal safetyVSAvoidthermal management structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The hollow copper conductor is nested between battery cells, with the coolant flow passage embedded within the copper structure itself. This nesting approach integrates the thermal management function directly into the spatial arrangement between cells, enabling efficient heat dissipation without adding external complex systems.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The copper conductor is formed as a thin ribbon with flexible geometry that can conform to the spaces between closely packed battery cells. The thin film structure allows the thermal management component to adapt to varying battery pack configurations while maintaining effective thermal contact.

Inventive Principle:

Principle #30Flexible shells and thin films

2Reliability

If hollow copper thermal conductors with complex geometries are used to improve heat dissipation, then thermal conductivity is enhanced, but manufacturing complexity increases

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoidconductor fabrication

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

A sacrificial insert is formed in advance with the desired hollow geometry, then copper is plated around it to create the final conductor structure. This preliminary action allows complex internal passages to be created without complex manufacturing processes, as the sacrificial insert defines the geometry and is later removed to reveal the hollow channels.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

A sacrificial material serves as an intermediary during manufacturing, occupying the space where the hollow passage will eventually exist. This mediator enables the creation of complex internal geometries through simple external plating processes, after which the sacrificial material is removed to reveal the desired structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If solid copper conductors are used for thermal management, then thermal conductivity is high, but compliance and adaptability to fit between battery cells is reduced

Engineering Contradiction:

Improvecompliance between cellsVSAvoidthermal conductivity

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The copper thermal conductor is formed as a thin ribbon structure that inherently possesses flexibility and compliance. This thin film geometry allows the conductor to conform to the irregular spaces between battery cells while maintaining continuous thermal contact, unlike rigid solid conductors.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The thermal management solution transitions from bulk three-dimensional solid conductors to a two-dimensional thin ribbon structure. This dimensional change enables the conductor to wrap around and adapt to battery cell surfaces, maximizing thermal contact area while maintaining flexibility.

Inventive Principle:

Principle #17Another dimension (Dimensionality 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

The hollow copper thermal conductor provides enhanced thermal conductivity and compliance to fit between battery cells, actively cooling them through liquid or gas coolant flow, thereby improving battery pack performance and safety.

Implementation Method 1

Plating the sacrificial insert with copper to form a ribbon-shaped structure

Methodology Applied

Scientific EffectElectroplating: Electroplating

Implementation Method 2

removing the sacrificial material from the within the copper plated coil shaped member includes one of melting, burning, and dissolving the sacrificial material

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 3

The hollow copper thermal conductor provides enhanced thermal conductivity and compliance to fit between battery cells, actively cooling them through liquid or gas coolant flow

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS20240234859A1Hollow copper thermal conductors

Publication Date: 2024.07.11 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A process for making a ribbon-shaped hollow thermal conductor includes forming a sacrificial material into an insert including a plurality of parallel strands. Plating the sacrificial insert with copper to form a ribbon-shaped structure and removing the sacrificial material from within the ribbon-shaped structure to create a hollow passage through a ribbon-shaped hollow copper thermal conductor.