Phase Change Composite Thermal Switch for Passive Heat Dissipation
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Solution Overview
Problem
Existing temperature regulation methods for battery packs and electronic devices are inadequate, lacking efficient passive thermal management systems that can actively respond to heat levels without requiring active cooling mechanisms.
Innovation Solution
A passive thermal management system using a thermally responsive phase change composite (PCC) that expands upon heating to connect conductive elements, increasing thermal conductivity and acting as a 'smart' thermal switch, with a support structure containing cavities or cells filled with PCC materials like paraffin wax or hydrated salts in a graphite matrix.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If passive thermal management is implemented without active cooling mechanisms, then device complexity is reduced, but thermal management effectiveness is insufficient
Solution Approach 1:
The patent employs phase change materials that undergo parameter changes (phase transitions) at specific temperature thresholds. When the battery temperature reaches the phase change point, the material transitions from solid to liquid, absorbing latent heat and effectively controlling temperature without requiring complex active cooling systems.
Solution Approach 2:
The patent uses composite structures combining phase change materials with graphite matrix or other conductive materials. This composite approach enhances thermal conductivity while maintaining passive operation, resolving the contradiction between simplicity and effectiveness by creating a material that automatically responds to temperature changes.
2Use of energy by moving object
If phase change materials are used for heat storage and release, then thermal energy management is improved, but thermal response precision is insufficient
Solution Approach 1:
The patent divides the thermal management system into multiple independent phase change material units or layers, each potentially with different phase change temperatures. This segmentation allows for precise thermal response at different temperature levels, improving both energy management and response precision simultaneously.
Solution Approach 2:
Different regions of the thermal management system use phase change materials with locally optimized properties (different phase change temperatures, latent heats). This allows precise thermal control tailored to specific heat generation zones within the battery pack, enhancing both energy management and temperature precision.
3Temperature
If thermally responsive material expands upon heating to connect conductive elements, then thermal conductance increases, but material structural stability deteriorates
Solution Approach 1:
The patent encloses phase change materials in flexible encapsulation layers or thin films that can accommodate volume changes during phase transitions. These flexible containers maintain structural integrity while allowing the material to expand upon heating, preventing leakage and maintaining stability during thermal cycling.
Solution Approach 2:
The patent uses porous matrix materials (such as graphite foam or porous ceramics) to contain phase change materials. The porous structure provides mechanical support and maintains structural stability while allowing thermal conduction, preventing the expanding material from compromising overall structural integrity.
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 effectively manages thermal energy transfer by activating at defined heat levels, enhancing heat dissipation from heat sources like battery packs, without active cooling, and allowing for targeted heat transfer and reuse of the PCC material.
Implementation Method 1
The phase change material can be contained in a composite matrix material (e.g., graphite), and can be any suitable material, such as a paraffin wax, a hydrated salt, and combinations thereof
Implementation Method 2
The thermally responsive material that expands upon absorbing thermal energy from the heat source
Implementation Method 3
The thermally responsive material changes from thermally insulating to thermally conductive upon the heating
Data Source
AI summary
A thermal management apparatus and method of use, such as in a battery pack or electronic device. A thermally responsive material is disposed between two surfaces, wherein the thermally responsive material changes upon heating, to increase a thermal conductance between the two surfaces. The thermally responsive material is offset from one of the surfaces and expands upon heating to connect the two surfaces. The thermally responsive material is a phase change composite including a phase change material selected from a paraffin wax, a hydrated salt, and combinations thereof.