Zigzag Dissipation Element for Round Cell Battery Thermal Management
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Solution Overview
Problem
Round cell rechargeable batteries face challenges in heat dissipation due to the electrical potential of the cell cans, which intensifies the heat dissipation problem.
Innovation Solution
A round cell rechargeable battery design featuring a zigzag-shaped thermally-conductive dissipation element, electrically insulated from the cells, combined with an electrically-insulating, thermally-conductive rubber-elastic thermoplastic elastomer to effectively dissipate heat from the cells to the dissipation element, which is then transferred to a coolant.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a dissipation element is used to dissipate heat from round cells, then heat dissipation efficiency is improved, but electrical insulation between the dissipation element and round cells becomes critical and complex
Solution Approach 1:
The patent introduces a thermoplastic elastomer as an intermediary material between the dissipation element and the round cells. This elastomer serves dual functions: it provides electrical insulation to prevent short circuits while simultaneously conducting heat from the cells to the dissipation element. The elastomer acts as a mediator that resolves the contradiction by enabling thermal transfer without electrical conduction.
Solution Approach 2:
The patent employs a composite material system consisting of the dissipation element (metallic, thermally conductive), the thermoplastic elastomer (electrically insulating yet thermally conductive), and the round cells. This composite structure allows the system to achieve both efficient heat dissipation and reliable electrical insulation by combining materials with complementary properties.
2Temperature
If thermally-conductive material is used to connect round cells, then heat dissipation is improved, but electrical insulation must be maintained simultaneously
Solution Approach 1:
The thermoplastic elastomer serves as an intermediary layer that enables thermal conduction while blocking electrical conduction. It is positioned between the dissipation element and the round cells, allowing heat to flow through it to the dissipation element while its electrical insulation properties prevent any electrical contact or short circuiting.
Solution Approach 2:
The patent applies the principle of local quality by using a material (thermoplastic elastomer) that has different functional properties at different aspects: it is electrically insulating to prevent short circuits, yet thermally conductive to enable heat transfer. This local differentiation of material properties allows simultaneous achievement of electrical reliability and thermal efficiency.
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 solution ensures efficient heat dissipation by preventing air gaps and enhancing thermal conduction, maintaining electrical insulation while allowing effective heat transfer, thus improving the battery's thermal management.
Implementation Method 1
an electrically-insulating, thermally-conductive, rubber-elastic thermoplastic elastomer, which is arranged at least partially between the dissipation element and the round cells to insulate the dissipation element electrically from the round cells and to dissipate heat from the round cells to the dissipation element
Implementation Method 2
a dissipation element that is electrically insulated from the round cells and connects a group of round cells in thermally-conductive fashion so as to dissipate heat
Data Source
AI summary
A round cell rechargeable battery includes a plurality of round cells arranged next to one another and a dissipation element that is electrically insulated from the round cells and connects a group of round cells in thermally-conductive fashion so as to dissipate heat. The dissipation element is in the form of a rod and is bent in such a way that it runs in zigzag fashion alternately in each case along a lower side, an adjoining side wall, and an upper side of the round cells. The battery also includes an electrically-insulating, thermally-conductive, rubber-elastic thermoplastic elastomer, which is arranged at least partially between the dissipation element and the round cells to insulate the dissipation element electrically from the round cells and to dissipate heat from the round cells to the dissipation element.