Sealed Battery Pack Airflow Structure for Internal Thermal Cooling
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Solution Overview
Problem
Existing sealed battery packs face challenges in effectively managing thermal cooling within a sealed housing, which can lead to reduced performance and lifespan due to heat buildup.
Innovation Solution
The battery pack assembly incorporates a housing with a fan to circulate air through a battery cell assembly, which includes a frame supporting battery cells and a heat sink with projections for enhanced heat transfer. Additionally, airflow tunnels and baffles are used to direct airflow and improve cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sealed housing is used for the battery pack, then protection against environmental factors is improved, but thermal cooling management deteriorates due to heat buildup
Solution Approach 1:
A fan is introduced as an intermediary device within the sealed housing to actively circulate air through the battery cell assembly. The fan creates forced convection currents that move heat away from the battery cells, allowing the sealed housing to maintain both its protective function and effective thermal management through active air circulation rather than passive cooling
Solution Approach 2:
The patent utilizes pneumatic principles by implementing a forced air circulation system. Air is moved through the battery assembly using a fan-driven flow path that channels cooling air across the battery cells and exhausts heated air, creating a controlled pneumatic cooling environment within the sealed housing
2Temperature
If air circulation is implemented within the sealed housing, then thermal cooling is improved, but device complexity increases
Solution Approach 1:
The housing structure is designed to serve multiple functions: it provides structural support, environmental protection, and integrated thermal management pathways. The same housing walls that provide sealing also serve as airflow channels and heat dissipation surfaces, eliminating the need for separate dedicated cooling components and reducing overall system complexity
Solution Approach 2:
The cooling airflow path is merged with the housing structure itself. Airflow tunnels and channels are formed as integral parts of the housing design rather than as separate add-on components. This integration combines the protective enclosure function with the thermal management function into a single unified structure
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 thermal cooling within the sealed housing, effectively managing heat and improving the performance and lifespan of the battery pack.
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 with projections for enhanced heat transfer
Implementation Method 3
airflow tunnels and baffles are used to direct airflow and improve cooling efficiency
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.