Layered Battery Pack With PCM Pouches and Foam for Fast Charging
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Solution Overview
Problem
Mobile device battery packs face challenges with high charging times and overheating due to high currents, which can lead to safety issues like melting or fires, and also experience physical expansion due to thermal effects, requiring effective thermal management and accommodation of size variability.
Innovation Solution
Incorporating phase change material (PCM) pouches within the battery pack to absorb and release thermal energy, combined with elastic materials like foam to manage expansion and prevent pressure buildup, while using a rigid-flex PCB and temperature sensors for controlled charging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high charging current is used to reduce charging time, then charging speed is improved, but temperature increases causing overheating and safety issues
Solution Approach 1:
The patent incorporates phase change material (PCM) pouches that undergo phase transitions (solid-liquid) at specific temperatures to absorb excess thermal energy during high-rate charging. The PCM pouches are positioned in thermal contact with battery cells to capture heat during charging and release it during discharging or low-usage periods, enabling sustained high C-rate charging without dangerous temperature buildup.
2Productivity
If high charging current is used to reduce charging time, then charging speed is improved, but thermal losses increase causing heat generation
Solution Approach 1:
The patent converts the harmful thermal energy lost during high-rate charging into a beneficial resource by using PCM pouches to capture and store this waste heat. The stored thermal energy is then released during discharging or low-usage periods, effectively recycling energy that would otherwise be wasted and reducing the need for active cooling systems.
3Device complexity
If battery cells are allowed to expand due to thermal effects, then thermal management is simplified, but structural integrity deteriorates due to pressure buildup
Solution Approach 1:
The patent employs elastic foam materials positioned around battery cells that can compress and expand to accommodate cell dimensional changes during charging and discharging cycles. This flexible cushioning approach allows thermal expansion without generating dangerous pressure buildup, maintaining structural integrity while simplifying thermal management by eliminating rigid constraints.
4Strength
If rigid structure is used to prevent expansion, then structural integrity is maintained, but thermal management efficiency decreases
Solution Approach 1:
The patent transitions from static rigid structural constraints to dynamic flexible foam cushioning that adapts to real-time thermal and mechanical conditions. The elastic foam maintains structural support while dynamically adjusting to accommodate battery cell expansion during charging and contraction during discharging, optimizing both mechanical protection and thermal management efficiency throughout the battery lifecycle.
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 faster charging without overheating, maintains battery pack safety, and accommodates physical expansion, reducing the risk of damage and ensuring efficient thermal management.
Implementation Method 1
phase change material (PCM) pouches include PCM material that transitions between physical states (e.g., from solid to liquid). The phase transitions of the PCM may be endothermic or exothermic. For example, PCM pouch(es) sink or store thermal produced by battery cells energy during charging
Implementation Method 2
The phase transitions of the PCM may be endothermic or exothermic. For example, PCM pouch(es) sink or store thermal produced by battery cells energy during charging
Implementation Method 3
foam or other elastic material may be included in the stack of elements in the battery pack. The elastic material (e.g., foam) may decrease in dimension as a result of the battery cell and or PCM pouch swelling, thereby preventing an increase in pressure for the battery cell
Data Source
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AI summary
A rechargeable battery pack may include at least one rechargeable battery cell and at least one phase change material (PCM) pouch in contact with the at least one rechargeable battery cell within a housing. The battery pack may include electrical conductors electrically connected to the at least one rechargeable battery cell to enable electrical power to be conducted to and from the at least one rechargeable battery cell. A compressible element, such as a foam element, may be positioned between a PCM pouch and an inside wall of the housing, thereby absorbing swelling of the rechargeable battery cell(s) to reduce risk of damage to the battery cells and battery pack. The electrical conductors may be formed on a rigid-flex printed circuit board (PCB).