Layered Pouch-Cell Battery Pack With Tray-Based Heat Dissipation
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Solution Overview
Problem
Current energy storage systems for automobiles face challenges with high production costs and reliability issues due to the use of lithium batteries, and existing solutions either result in unused space or inefficient heat dissipation in battery packs.
Innovation Solution
A battery pack design that groups flat-pouch cells in layers at the center, connected to planar trays for heat dissipation using their terminals, without adhesives, allowing for efficient cooling and monitoring while optimizing volume and ensuring electrical connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If small cylindrical batteries are connected in series in strings, then voltage and current values compatible with the inverter are obtained, but a lot of unused space results and energy density could be improved
Solution Approach 1:
The patent transitions from cylindrical to flat-pouch battery cells, changing the geometric dimension from three-dimensional cylinders to flattened pouches. This dimensional change allows the batteries to be stacked more efficiently in layers, filling the available space in the battery pack container and eliminating unused gaps, thereby improving energy density while maintaining compact volume.
Solution Approach 2:
The battery pack is divided into multiple layers of flat-pouch cells, with each layer containing multiple cells arranged in series. These layers are then connected in parallel to achieve the desired voltage and current values. This segmentation allows for optimized space utilization and improved energy density compared to single-string cylindrical configurations.
2Ease of manufacture
If cells are stacked without casing one on top of the other, then production costs are reduced, but reliability of the battery pack is not assured
Solution Approach 1:
The patent introduces planar trays as intermediary components between the flat-pouch cells. These trays serve multiple functions: they provide structural support and protection for the cells, facilitate heat dissipation through thermal contact with cooling elements, and enable reliable electrical connections. This intermediary structure ensures battery pack reliability while maintaining cost-effectiveness.
Solution Approach 2:
The planar trays perform multiple functions simultaneously: mechanical support, thermal management, and electrical connection. This multi-functionality reduces the need for separate protective casings and components, lowering production costs while ensuring reliable operation through integrated design.
3Temperature
If cells are connected to heat dissipating elements, then heat exchange is improved, but the connection may affect heat exchange if adhesives are used
Solution Approach 1:
The patent replaces adhesive-based mechanical connections with direct thermal contact through planar trays. The trays are positioned in direct contact with the cells, allowing heat to conduct efficiently from the cells to the cooling elements without the thermal resistance introduced by adhesives. This mechanical arrangement preserves heat exchange efficiency while achieving reliable connection.
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 design enhances energy density, reduces production costs, and improves reliability by optimizing heat exchange and cell monitoring, ensuring efficient operation and safety of the battery pack.
Implementation Method 1
connect such layers to planar-shaped trays suitable to dissipate the heat produced by said cells
Implementation Method 2
first lateral walls, arranged opposite one another, have the purpose of cooling down the cells
Data Source
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AI summary
A vehicular battery pack (BP) comprising a parallelepiped-shaped container, wherein cells (C) are grouped in layers (L) one above the other in the container, wherein each of said battery layers is connected to a face of a substantially planar-shaped tray (T) through relative terminals (C+, C-) of the same cells.