Integrated Heat Fin Battery Cell Thermal Management

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Solution Overview

Problem

There is a need for improved power sources and battery systems in xEVs that increase travel distance without recharging, enhance performance, and reduce costs, while also addressing packaging challenges in converting traditional vehicles to hybrid electric vehicles.

Innovation Solution

The integration of an internal heat fin within the pouch of lithium ion battery cells, which facilitates efficient heat transfer and simplifies battery module assembly, using a metallic foil layer and electrically insulating layers to hermetically seal the electrochemical stack, allowing for the provision of multiple voltages from a form factor equivalent to a traditional lead acid battery.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Duration of action of moving object

If battery cell size is increased to extend travel distance, then energy capacity is improved, but thermal management becomes more difficult and safety risks increase

Engineering Contradiction:

Improvetravel distance without rechargingVSAvoidheat dissipation difficulty

Core Design Contradiction:

Duration of action of moving objectVSTemperature

Solution Approach 1:

The patent combines the heat fin structure directly with the pouch encapsulation material, merging thermal management functionality into the existing cell structure. This integration allows efficient heat dissipation from large-capacity cells without requiring separate cooling systems, resolving the contradiction between extended travel distance and thermal management difficulty.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The heat fin acts as an intermediary component between the electrochemical stack and the external environment. It conducts heat away from the cell interior through its extended surface area, enabling large-capacity cells to maintain safe operating temperatures despite increased energy storage.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If multiple components are integrated into battery cells to improve performance, then functionality is enhanced, but device complexity increases

Engineering Contradiction:

Improveperformance enhancementVSAvoidcell structure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The heat fin is merged with the pouch material to form an integrated component rather than a separate part. This combination enhances thermal management functionality while avoiding the complexity of assembling multiple discrete components, as the heat fin becomes an inherent part of the pouch structure.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The pouch material serves multiple functions: it provides mechanical encapsulation, electrical insulation, and thermal management through the integrated heat fin. This multi-functionality enhances cell performance without increasing complexity, as a single component performs multiple roles.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If advanced thermal management features are added to battery cells, then safety and performance are improved, but manufacturing complexity increases

Engineering Contradiction:

Improvethermal management efficiencyVSAvoidassembly simplicity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The heat fin is formed as an integral part of the pouch during the pouch manufacturing process, combining thermal management features with the encapsulation structure. This integration simplifies manufacturing by eliminating separate heat fin assembly steps while maintaining effective thermal management.

Inventive Principle:

Principle #5Merging (Combining)

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 enhances the thermal management and assembly efficiency of battery modules, enabling longer travel distances, improved performance, and reduced costs, while allowing for seamless integration into traditional vehicle platforms, thus facilitating the conversion of vehicles to xEVs.

Implementation Method 1

a metallic foil layer disposed between a second electrically insulating layer and a third electrically insulating layer... sufficient conductive material to efficiently facilitate transfer of heat generated by the electrochemical cell to the end portions

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

The heat fin may include a generally U-shaped cross-section such that end portions can interact with a heat sink or the like and the heat fin may include sufficient conductive material to efficiently facilitate transfer of heat generated by the electrochemical cell to the end portions

Methodology Applied

Scientific EffectHeat transfer: Heat Exchanger

Data Source

PatentUS9287579B2Battery cell with integrated heat fin

Publication Date: 2016.03.15 CPS TECHNOLOGY HOLDINGS LLC

AI summary

A system includes a battery cell having an internal heat fin and a first electrically insulating layer disposed over at least a portion of a single side of the internal heat fin. The battery cell includes an electrochemical stack disposed above the first insulating layer and the internal heat fin in a stack. The battery cell also includes a pouch material film configured to hermetically seal with one side of the internal heat fin or the first insulating layer about the electrochemical stack such that the internal heat fin forms an outer boundary of the battery cell. The pouch material film includes a metallic foil layer disposed between a second electrically insulating layer and a third electrically insulating layer.