Sealed Battery Pack Airflow Structure for Thermal Dissipation
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Solution Overview
Problem
Existing battery pack designs face challenges in effectively managing thermal cooling within a sealed housing, which can lead to reduced performance and lifespan due to inadequate heat dissipation.
Innovation Solution
The battery pack assembly incorporates a housing with a fan, airflow tunnels, and a heat sink, along with thermally conductive materials and adhesive encapsulants to facilitate airflow and heat transfer, ensuring efficient thermal management within the sealed environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sealed housing is used to protect the battery pack, then reliability is improved, but heat dissipation deteriorates
Solution Approach 1:
The patent introduces thermal interface material as an intermediary substance between the battery cells and heat sink. This material facilitates heat transfer from the battery cells to the heat sink while maintaining the sealed housing structure, thus resolving the contradiction between sealed protection and heat dissipation.
Solution Approach 2:
The battery pack is segmented into distinct thermal zones with dedicated heat dissipation pathways. The housing includes integrated heat sinks and airflow channels that create separate thermal management zones, allowing the sealed structure to maintain protection while enabling effective heat removal through structured thermal pathways.
2Temperature
If thermal management components are added to improve heat dissipation, then temperature control is improved, but device complexity increases
Solution Approach 1:
The patent merges the housing structure with thermal management functions by integrating heat sinks directly into the housing walls and incorporating airflow channels within the housing structure itself. This consolidation eliminates the need for separate thermal management components, reducing overall device complexity while maintaining effective heat dissipation.
Solution Approach 2:
The housing serves multiple functions simultaneously: it provides mechanical protection, structural support, thermal management through integrated heat sinks, and airflow management through built-in channels. This multi-functionality reduces the need for additional dedicated components, thereby reducing device complexity while achieving comprehensive thermal control.
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 configuration enhances heat dissipation, improves battery pack performance, and extends cycle life by effectively managing thermal conditions within the sealed housing.
Implementation Method 1
The fan is configured to circulate air within the housing and through the battery cell assembly
Implementation Method 2
a heat sink integrated with the housing
Implementation Method 3
the heat sink is configured to transfer heat from the battery cells to the circulating air
Implementation Method 4
thermally conductive materials and adhesive encapsulants to facilitate airflow and heat transfer
Data Source
AI summary
A battery pack assembly includes a housing, a battery cell assembly, and a fan. The housing having a plurality of sides and defining an internal cavity. The battery cell assembly positioned in the internal cavity. The battery cell assembly includes a plurality of battery cells and a frame supporting the battery cells. The frame includes a first support member, a second support member, and a plurality of leg members connecting the first support member and the second support member. The first support member and the second support member each has a body extending between a first edge and a second edge opposite the first edge. The body defines a plurality of openings configured to align with one of the battery cells. The fan is configured to circulate air within the housing and through the battery cell assembly.