Description:FIELD OF THE INVENTION
The present invention relates to an advanced composite material-based battery enclosure. More specifically, it integrates aluminum mesh and carbon fiber composite to enhance thermal management and structural integrity for improved battery performance and safety.
BACKGROUND OF THE INVENTION
Currently, around 80% of EVs have an aluminum battery enclosure, with steel dominating the remainder, but empty metallic battery enclosures add 110-160 kilograms to vehicle mass and are now the heaviest component on battery electric vehicles (BEVs) and that’s before battery packs are loaded. Reducing weight of the vehicle and requiring careful thermal management are two major important considerations in battery enclosure. Composite with its lighter weight battery pack design in reducing the overall vehicle weight and thermal conduction is alter to metal solutions. Materials and electrical insulation are all important factors to consider when optimizing electric battery performance against potential thermal runaway. Considering the influence of the working temperature on the safety and performance of the battery system, thermal management is becoming increasingly important.
Battery enclosures play a crucial role in the performance and safety of energy storage systems, particularly in electric vehicles and high-power applications. Traditional enclosures made from either metal or polymer-based composites often struggle to balance thermal conductivity, weight, and structural strength. Excessive heat buildup within battery packs can lead to performance degradation, efficiency loss, and even safety hazards like thermal runaway.
The combination of carbon fiber and aluminum mesh offers a promising solution to these challenges. Carbon fiber provides exceptional mechanical strength and lightweight properties, while aluminum mesh contributes high thermal conductivity. The integration of these materials results in a hybrid structure capable of efficiently dissipating heat while maintaining structural rigidity. This novel approach addresses the limitations of conventional battery enclosures and ensures enhanced performance, longevity, and safety.
Basic Differences from Previous Solutions
1. Material Composition:
• Traditional Enclosures: Often made from single materials such as steel, aluminum, or plastic, which can limit their thermal and mechanical performance.
• Proposed Enclosure: Utilizes a hybrid structure combining aluminum and carbon composite mesh, enhancing both thermal management and structural integrity.
2. Thermal Conductivity:
• Traditional Solutions: May rely on less conductive materials or require additional cooling systems to manage heat, which can add weight and complexity.
• Proposed Solution: The inherent high thermal conductivity of aluminum and the effective heat spreading properties of carbon composites reduce the need for complex cooling systems, simplifying the design and improving efficiency.
3. Weight and Strength:
• Traditional Solutions: May involve heavier materials that increase the overall weight of the battery pack, potentially impacting the performance of EVs and other applications.
• Proposed Solution: Offers a lightweight yet strong enclosure, improving the performance and efficiency of applications by reducing weight without compromising on strength.
4. Customization and Flexibility:
• Traditional Solutions: Limited customization options due to the use of standard materials with fixed properties.
• Proposed Solution: Carbon composites can be engineered for specific needs, providing greater flexibility in design and application.
In summary, the proposed hybrid aluminum and carbon composite mesh battery enclosure provides significant advantages in thermal management, strength-to-weight ratio, corrosion resistance, and design flexibility, addressing limitations of previous solutions and offering a more efficient and robust option for modern battery systems.
SUMMARY OF THE INVENTION
This summary is provided to introduce a selection of concepts, in a simplified format, that are further described in the detailed description of the invention.
This summary is neither intended to identify key or essential inventive concepts of the invention and nor is it intended for determining the scope of the invention.
The present invention introduces a novel battery enclosure structure that combines carbon fiber and aluminum mesh using the hand lay-up method. This method involves manually placing layers of carbon fiber fabric and aluminum mesh in a mold, applying resin to each layer, and curing the composite under heat and pressure. The resulting hybrid material offers a unique balance of mechanical strength, lightweight characteristics, and efficient heat dissipation.
The integration of aluminum mesh within the carbon composite structure allows the battery enclosure to effectively transfer heat away from the battery cells during charging and discharging cycles. The heat generated by the battery pack is conducted through the aluminum mesh and dissipated into the surrounding environment or carried away by an external cooling system. This process minimizes thermal stress on the battery, reducing the risk of overheating and enhancing overall efficiency.
The proposed enclosure leverages the advantages of both carbon fiber and aluminum mesh. Carbon fiber provides superior structural rigidity and impact resistance, ensuring mechanical protection for battery cells. Simultaneously, aluminum mesh enhances thermal conductivity, enabling efficient heat transfer. The combination of these materials makes the enclosure highly suitable for high-performance battery systems where thermal management is critical.
Furthermore, the enclosure design is adaptable to various applications, including electric vehicles, aerospace, and portable energy storage devices. By addressing the fundamental issues of weight, durability, and heat dissipation, the invention significantly improves battery performance and extends operational lifespan.
To further clarify advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which is illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings.
Direct liquid cooling strategy for a large-scale lithium-ion pouch type cell is proposed to control the cell working temperature within the optimum range of performance and safety.
The usage of heat pipes (HPs) is considered one of the use full techniques to cool batteries due to its high thermal conductivity.
BRIEF DESCRIPTION OF THE DRAWINGS
The illustrated embodiments of the subject matter will be understood by reference to the drawings, wherein like parts are designated by like numerals throughout. The following description is intended only by way of example, and simply illustrates certain selected embodiments of devices, systems, and methods that are consistent with the subject matter as claimed herein, wherein:
FIGURE 1: OPEN VIEW
The figures depict embodiments of the present subject matter for the purposes of illustration only. A person skilled in the art will easily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.
DETAILED DESCRIPTION OF THE INVENTION
The detailed description of various exemplary embodiments of the disclosure is described herein with reference to the accompanying drawings. It should be noted that the embodiments are described herein in such details as to clearly communicate the disclosure. However, the amount of details provided herein is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the present disclosure as defined by the appended claims.
It is also to be understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of the present disclosure. Moreover, all statements herein reciting principles, aspects, and embodiments of the present disclosure, as well as specific examples, are intended to encompass equivalents thereof.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a",” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “includes” and/or “including,” when used herein, specify the presence of stated features, integers, steps, operations, elements and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and/or groups thereof.
It should also be noted that in some alternative implementations, the functions/acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may, in fact, be executed concurrently or may sometimes be executed in the reverse order, depending upon the functionality/acts involved.
In addition, the descriptions of "first", "second", “third”, and the like in the present invention are used for the purpose of description only, and are not to be construed as indicating or implying their relative importance or implicitly indicating the number of technical features indicated. Thus, features defining "first" and "second" may include at least one of the features, either explicitly or implicitly.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, e.g., those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
In the hand lay-up method for manufacturing carbon fiber and aluminum mesh composites, layers of carbon fiber fabric and aluminum mesh are manually placed in a mold. Resin is then applied to each layer to bind the materials together. The composite is carefully built up layer by layer to the desired thickness. Once the lay-up is complete, it is left to cure, often under heat and pressure, to solidify the composite structure.
• Aluminum mesh with carbon composite provide effective solutions for thermal conduction problems through their high thermal conductivity, lightweight nature and specific advantages tailored to different applications
• Combining carbon fiber and aluminum mesh can leverage the strengths of both materials.
• Carbon fiber can provide structural strength and rigidity, while aluminum can offer benefits in conductivity and thermal management.
• The composite structure can help in efficiently dissipating heat away from the battery, reducing the risk of overheating.
The proposed Battery enclosure surface is surrounded with aluminum mesh on carbon fiber composite. When the battery cells generate heat during charging and discharging cycles, the enclosure's material (aluminum mesh with carbon composite) conducts this heat away from the cells. The heat is transferred to the outer shell and dissipated into the environment or carried away by the cooling system.
The distinguishing feature of our battery enclosure design is the integration of a hybrid aluminum and carbon composite mesh structure that combines high thermal conductivity with superior strength-to-weight ratio, providing enhanced heat dissipation and structural integrity compared to traditional single-material enclosures.
The proposed battery enclosure comprises layers of carbon fiber fabric and aluminum mesh, carefully structured to optimize both mechanical strength and thermal conductivity. In the hand lay-up manufacturing process, individual layers of carbon fiber fabric and aluminum mesh are arranged sequentially within a mold. Resin is applied to each layer to ensure proper adhesion and structural integrity. Once the layers are assembled, the composite undergoes a curing process involving heat and pressure to achieve the final solidified structure.
The inclusion of aluminum mesh within the composite matrix is crucial for heat dissipation. As battery cells generate heat during charging and discharging, the high thermal conductivity of aluminum mesh facilitates the rapid transfer of heat away from the cells. This heat is conducted through the composite structure and dissipated into the environment, either passively through natural convection or actively through an integrated cooling system.
In addition to thermal management, the structural integrity of the enclosure is enhanced by the carbon fiber layers. Carbon fiber is known for its high strength-to-weight ratio, impact resistance, and durability. The hybrid composite design ensures that the battery pack remains secure even in high-vibration environments, making it suitable for automotive and aerospace applications.
The enclosure's unique design provides benefits beyond conventional metal or polymer-based enclosures. Traditional metal enclosures, while offering good thermal conductivity, are often heavy and susceptible to corrosion. Polymer-based enclosures, on the other hand, are lightweight but lack the necessary thermal conductivity to manage heat effectively. The proposed hybrid composite enclosure overcomes these drawbacks by combining the best attributes of both materials.
Another critical feature of the invention is its adaptability to various configurations. The lay-up process allows for customization in terms of thickness, layering sequence, and resin composition, enabling the enclosure to be tailored to specific battery pack requirements. Additionally, the enclosure design can be integrated with existing battery management systems (BMS) to enhance real-time monitoring and control of thermal conditions.
The use of aluminum mesh also improves electromagnetic shielding, reducing electromagnetic interference (EMI) and enhancing the reliability of the battery system. This feature is particularly beneficial for applications in electric vehicles and aerospace, where EMI mitigation is essential for system performance.
To further enhance heat dissipation, the enclosure can incorporate external cooling fins or heat sinks, allowing for more efficient thermal regulation. Additionally, phase change materials (PCMs) may be integrated into the composite structure to provide passive cooling capabilities during peak thermal loads.
Overall, the proposed battery enclosure design offers an innovative approach to addressing the challenges of thermal management and structural integrity in battery systems. The combination of carbon fiber and aluminum mesh provides a highly effective solution, ensuring safety, efficiency, and longevity.
ADVANTAGES OF THE INVENTION
Enhanced Thermal Management:
• Hybrid Material Structure: By combining aluminum and carbon composite mesh, the enclosure leverages aluminum's high thermal conductivity (~205 W/m·K) and the customizable thermal properties of carbon composites. This dual approach ensures efficient heat dissipation, maintaining battery temperatures within safe operating limits and preventing thermal runaway
• .Improved Heat Distribution: The aluminum mesh rapidly conducts heat away from hot spots, while the carbon composite helps in spreading and dissipating the heat evenly across the enclosure surface.
2. Superior Strength-to-Weight Ratio:
• Lightweight Design: Carbon composites offer high mechanical strength while being significantly lighter than metals, reducing the overall weight of the battery pack. This is particularly beneficial for electric vehicles (EVs) and aerospace applications where weight savings are critical.
• Structural Integrity: The combined use of aluminum and carbon composites ensures that the enclosure is robust and can withstand mechanical stresses and impacts, providing better protection for the battery cells compared to traditional enclosures made solely from metals or plastics.
3. Corrosion Resistance:
• Material Durability: Aluminum naturally forms an oxide layer that protects it from corrosion, enhancing the longevity of the enclosure in various environmental conditions. Carbon composites are also resistant to corrosion and chemical degradation, adding to the overall durability of the enclosure.
4. Customizable Properties:
• Tailorable Composite Design: Carbon composites can be engineered to exhibit specific thermal and mechanical properties, allowing for customization based on the specific requirements of different battery systems. This flexibility in design is a significant advantage over traditional materials that offer limited customization options.
, Claims:1. A battery enclosure comprising a hybrid composite structure of carbon fiber and aluminum mesh, designed to enhance thermal management and structural integrity.
2. The battery enclosure as claimed in claim 1, wherein the aluminum mesh facilitates heat dissipation by conducting thermal energy away from battery cells.
3. The battery enclosure as claimed in claim 1, wherein the carbon fiber provides mechanical strength and impact resistance.
4. The battery enclosure as claimed in claim 1, further comprising a resin matrix that binds the layers of carbon fiber and aluminum mesh together.
5. The battery enclosure as claimed in claim 1, wherein the composite structure is manufactured using the hand lay-up process.
6. The battery enclosure as claimed in claim 1, wherein the enclosure is designed for electric vehicle battery systems.
7. The battery enclosure as claimed in claim 1, wherein the hybrid composite structure enhances electromagnetic shielding and reduces electromagnetic interference.
8. The battery enclosure as claimed in claim 1, further comprising integrated cooling fins or heat sinks to enhance thermal dissipation.
9. The battery enclosure as claimed in claim 1, wherein phase change materials (PCMs) are embedded to provide passive thermal regulation.
 
10. The battery enclosure as claimed in claim 1, wherein the enclosure is adapted to integrate with battery management systems (BMS) for real-time monitoring of thermal conditions.