Battery pack with variable-conductance heat pipe (VCHP) cooling

• US 9,923,252 B2
• Filed: 10/12/2015
• Issued: 03/20/2018
• Est. Priority Date: 12/17/2014
• Status: Active Grant

• Current Assignee: Wing Aviation LLC (Alphabet Inc.)
• Original Assignee: X Development LLC (Alphabet Inc.)
• Inventors: Nubbe, Matthew A.
• Primary Examiner(s): Gilliam, Barbara L
• Assistant Examiner(s): McConnell, Wyatt P
• Application Number:
  US14/880,857
• Publication Number:
  US 20160181676A1
• Time in Patent Office: 890 Days
• Field of Search: None
• CPC Class Codes: H01M 10/613 Cooling or keeping cold
• CPC Class Codes: H01M 10/625 Vehicles
• CPC Class Codes: H01M 10/64 characterised by the shape of the cells
• CPC Class Codes: H01M 10/653 characterised by electrically insulating or thermally conductive materials
• CPC Class Codes: H01M 10/6551 Surfaces specially adapted for heat dissipation or radiation, e.g. fins or coatings
• CPC Class Codes: H01M 10/6552 Closed pipes transferring heat by thermal conductivity or phase transition, e.g. heat pipes
• CPC Class Codes: H01M 2220/20 Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 50/209 adapted for prismatic or rectangular cells H01M50/216 takes precedence
• CPC Class Codes: H01M 50/24 adapted for protecting batteries from their environment, e.g. from corrosion thermal insulation H01M10/658
• CPC Class Codes: H01M 50/271 Lids or covers for the racks or secondary casings
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

An apparatus including a battery pack comprising a plurality of individual batteries arranged around a battery cavity such that each individual battery is in thermal contact with at least one neighboring individual battery. A variable-conductance heat pipe (VCHP) having an evaporator end and a condenser end, is positioned so that at least part of the evaporator end being positioned in the battery cavity and in thermal contact with each of the plurality of individual batteries. The apparatus includes a thermally insulating cover having an inside and an outside, wherein the battery pack and the part of the VCHP evaporator end in the battery cavity are positioned inside the thermally insulating cover and at least part of the condenser end of the VCHP is outside the thermally insulating cover, and wherein the VCHP is substantially the only thermal path between the battery pack and the outside. Other implementations are disclosed and claimed.

Claims

1. An apparatus comprising:

a thermally insulating cover forming an enclosure;

a battery pack comprising a plurality of individual batteries disposed within the enclosure, wherein the plurality of individual batteries are arranged around a battery cavity such that each individual battery is in thermal contact with at least one neighboring individual battery and all of the individual batteries of the battery pack within the enclosure are immediately adjacent to the battery cavity; and

a variable-conductance heat pipe, VCHP, having an evaporator end and a condenser end, at least part of the evaporator end being positioned in the battery cavity and in thermal contact with each of the plurality of individual batteries within the enclosure,

wherein the battery pack and the part of the VCHP evaporator end in the battery cavity are positioned inside the enclosure formed by the thermally insulating cover and at least part of the condenser end of the VCHP is external to the thermally insulating cover, and wherein the VCHP is substantially the only thermal path between the battery pack and an outside of the enclosure formed by the thermally insulating cover.

2. The apparatus of claim 1, further comprising a radiator thermally coupled to the condenser end of the VCHP, the radiator including a plurality of heat-conducting fins.

3. The apparatus of claim 1, further comprising a thermal interface material, TIM, disposed in the cavity between the individual batteries and the evaporator end of the VCHP.

4. The apparatus of claim 3 wherein the TIM is a thermal paste or a thermally conductive adhesive.

5. The apparatus of claim 1 wherein the plurality of individual batteries includes six batteries arranged around the cavity in a substantially hexagonal arrangement.

6. The apparatus of claim 1, further comprising one or more additional battery packs each having a corresponding battery cavity therein within which at least part of the evaporator end is positioned so that at least part of the evaporator end is in thermal contact with the individual batteries in each of the one or more additional battery packs.

7. The apparatus of claim 6 wherein the battery pack and the one or more additional battery packs are positioned within the same thermally insulating cover.

8. The apparatus of claim 6 wherein the battery pack and the one or more additional battery packs are positioned within different thermally insulating covers.

9. The apparatus of claim 1 wherein the individual batteries in the battery pack are substantially cylindrical.

10. The apparatus of claim 9 wherein the individual batteries have a circular cross-sectional shape.

11. The apparatus of claim 1 wherein the individual batteries have a quadrilateral cross-sectional shape.

12. The apparatus of claim 1 wherein the individual batteries have a substantially trapezoidal cross-section with one side of the trapezoidal cross-section shaped to substantially match an exterior shape of the VCHP.

13. A system comprising:

a battery containment pod comprising;

a body formed of a material, the body having an exterior shape and an interior cavity formed in the material, the size and shape of the interior cavity designed to accommodate a battery assembly,

an exterior coating covering the exterior shape of the body, and

an attachment structure formed in or on the body to allow the body to be coupled to a flight vehicle; and

a battery assembly positioned within the battery containment pod, the battery assembly comprising;

a thermally insulating cover forming an enclosure;

a battery pack comprising a plurality of individual batteries disposed within the enclosure, wherein the plurality of individual batteries are arranged around a battery cavity such that each individual battery is in thermal contact with at least one neighboring individual battery and all of the individual batteries of the battery pack within the enclosure are immediately adjacent to the battery cavity; and

a variable-conductance heat pipe, VCHP, having an evaporator end and a condenser end, at least part of the evaporator end positioned within the battery cavity and in thermal contact with each of the plurality of individual batteries within the enclosure and at least part of the condenser end positioned outside the battery containment pod,

wherein the battery pack and the part of the VCHP evaporator end in the battery cavity are positioned inside an enclosure formed by the thermally insulating cover and at least part of the condenser end of the VCHP is external to the enclosure formed by the thermally insulating cover, and wherein the VCHP is substantially the only thermal path between the battery pack and an outside of the enclosure formed by the thermally insulating cover.

14. The system of claim 13, further comprising a radiator thermally coupled to the condenser end of the VCHP, the radiator including a plurality of heat-conducting fins.

15. The system of claim 13, further comprising a thermal interface material, TIM, disposed in the cavity between the individual batteries and the evaporator end of the VCHP.

16. The system of claim 15 wherein the TIM is a thermal paste or a thermally conductive adhesive.

17. The system of claim 13 wherein the plurality of individual batteries includes six batteries arranged around the battery cavity in a substantially hexagonal arrangement.

18. The system of claim 13, further comprising one or more additional battery packs each having a corresponding battery cavity therein within which at least part of the evaporator end is positioned so that at least part of the evaporator end is in thermal contact with the individual batteries in each of the one or more additional battery packs.

19. The system of claim 18 wherein the battery pack and the one or more additional battery packs are positioned within the same thermally insulating cover.

20. The system of claim 19 wherein the battery pack and the one or more additional battery packs are positioned within different thermally insulating covers.

21. The system of claim 13 wherein the individual batteries in the battery pack are substantially cylindrical.

22. The system of claim 21 wherein the individual batteries have a circular cross-sectional shape.

23. The system of claim 13 wherein the individual batteries have a quadrilateral cross-sectional shape.

24. The system of claim 13 wherein the individual batteries have a substantially trapezoidal cross-section with one side of the trapezoidal cross-section shaped to substantially match an exterior shape of the VCHP.