Modular Battery Pack Thermal Management via Conductive Housing

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Solution Overview

Problem

Existing battery packs face challenges in heat dissipation, safety, and performance, particularly in high-energy density applications, with risks of explosion and fire due to excessive heat generation, and lack effective secondary safeguards for catastrophic failures, especially in remote environments with varying conditions.

Innovation Solution

A modular sealed battery pack system with a thermally conductive structural housing, a vent assembly for gas exchange and pressure relief, and an electronic circuit for monitoring and controlling battery conditions, including a release latch for safe detachment and condition determination.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If higher energy density battery cells are used to increase capacity and output power, then battery performance is improved, but heat generation increases and safety risks (explosion, fire) worsen

Engineering Contradiction:

Improvebattery capacity and output powerVSAvoidheat generation and safety risks

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent converts the harmful heat generated by high-energy-density battery cells into a beneficial thermal management opportunity by implementing a thermally conductive housing that actively dissipates heat. The housing structure itself becomes a heat sink, transforming the problematic heat generation into a controlled thermal dissipation process that maintains safety while preserving high energy density.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The thermally conductive housing acts as an intermediary between the battery cells and the external environment. It mediates heat transfer from the cells to the surrounding air, providing a controlled thermal pathway that prevents heat accumulation and associated safety risks while allowing the high-energy-density cells to operate at full capacity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Temperature

If forced air cooling systems (fans) are used to dissipate heat, then heat dissipation performance is improved, but device volume and power requirements increase

Engineering Contradiction:

Improveheat dissipation rateVSAvoidbattery pack volume

Core Design Contradiction:

TemperatureVSVolume of stationary object

Solution Approach 1:

The patent extracts the active cooling mechanism (fan) from the system and replaces it with a passive thermal management approach. The thermally conductive housing itself performs the cooling function through conductive and convective heat transfer, eliminating the need for mechanical cooling components and their associated volume and power requirements.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The battery pack housing provides its own thermal management function without requiring external active cooling systems. The thermally conductive material in the housing naturally dissipates heat from the battery cells through conduction and convection, allowing the system to self-regulate temperature without additional power consumption or mechanical components.

Inventive Principle:

Principle #25Self-service

3Temperature

If unsealed battery packs with vents are used to release heat and pressure, then heat dissipation is improved, but protection against moisture and environmental hazards worsens

Engineering Contradiction:

Improveheat release capabilityVSAvoidmoisture ingress and environmental damage

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The patent merges the functions of heat dissipation and environmental protection into a single integrated housing structure. The thermally conductive housing simultaneously provides thermal management pathways and sealed protection against moisture, combining what were previously separate functions (vents for heat release and seals for moisture protection) into one unified system.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The housing structure serves multiple functions: it provides structural support, acts as a thermally conductive heat sink, and serves as a sealed barrier against environmental hazards. This multi-functional design eliminates the need for separate venting mechanisms that would compromise the seal, allowing the housing to protect against moisture while still enabling heat dissipation through its thermal conductivity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 system enhances safety and performance by effectively managing heat, preventing adverse events like explosions and fires, while ensuring reliable operation in diverse environments through controlled venting and real-time monitoring.

Implementation Method 1

a thermally conductive structural housing element configured to house a battery assembly in an interior volume

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

a vent assembly configured to allow exchange of gases to and from the interior volume

Methodology Applied

Scientific EffectPressure-driven gas flow: Pressure Gradient

Data Source

PatentUS11476539B1Modular battery pack apparatus, systems, and methods including viral data and/or code transfer

Publication Date: 2022.10.18 SEESCAN INC

AI summary

Intelligent modular battery pack assemblies and associated charging and docking systems are disclosed.