Variable Gap Filler Battery Pack Cooling for Thermal Equilibrium
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Solution Overview
Problem
Conventional battery pack cooling structures using gap fillers fail to achieve thermal equilibrium due to temperature deviations between high and low heat generation areas, leading to battery cell swelling and reduced lifetime.
Innovation Solution
A battery pack cooling structure with a variable thickness gap filler and stepped or inclined lower plate design to induce thermal equilibrium by optimizing heat transfer through a thermal conductive material, reducing temperature differences between high and low heat generation areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a uniform thickness gap filler is applied on the lower plate, then the manufacturing process is simple, but thermal equilibrium cannot be achieved due to temperature deviation between central and edge portions
Solution Approach 1:
The lower plate is designed with different thicknesses in different regions: a first thickness in the central portion and a second thickness (greater than the first) in the edge portion. This local variation in thickness creates different thermal resistance paths, allowing the central high-temperature region to dissipate heat more effectively while maintaining appropriate thermal conditions at the edges, thereby achieving thermal equilibrium across the battery pack.
2Reliability
If a variable thickness lower plate design is applied, then thermal equilibrium is achieved, but manufacturing complexity increases
Solution Approach 1:
The lower plate incorporates localized thickness variations with a first thickness in the central portion and a second greater thickness at the edge portion. This design targets the specific thermal problem where the central battery modules generate more heat, creating a tailored thermal management solution that prevents overheating and swelling while remaining manufacturable through standard forming processes.
3Temperature
If gap filler is applied only at edge portions, then manufacturing is simplified, but heat transfer from central portion is insufficient
Solution Approach 1:
The gap filler is applied selectively at the edge portion of the lower plate where the second greater thickness is located, rather than uniformly across the entire surface. This localized application targets the thermal management needs at the edges while the variable thickness design itself provides the primary thermal resistance modulation for the central region, creating an efficient two-part thermal management approach.
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
Enhances thermal circulation efficiency, minimizing temperature deviations and extending the battery pack's lifetime by ensuring uniform heat distribution.
Implementation Method 1
a gap filler made of a thermal conductive material is applied on a lower plate of the battery pack on which the plurality of battery modules are seated
Data Source
AI summary
A battery pack cooling structure includes a battery module having a structure in which a plurality of battery cells are electrically connected and are accommodated in a case, and a battery pack having a structure in which a plurality of battery modules are electrically connected to each other, wherein a gap filler made of a thermal conductive material is applied on a lower plate of the battery pack on which the plurality of battery modules are seated, and an upper portion of the lower plate cover of the lower plate is formed to be stepped from an edge portion of the lower plate in which the plurality of battery modules are installed toward a central portion of the lower plate in which relatively more of the plurality of battery modules are installed.