Powder mixtures for heat dissipation and components having the powder mixtures

Abstract

A powder mixture (16) for heat dissipation and a method for producing the powder mixture (16) are disclosed. The powder mixture (16) is C 15 H 24 The powder mixture (16) includes two or more materials selected from the group consisting of: carbonates, oxides, oxalates, and chlorides, and one or more transition metal sources. A part having the powder mixture (16) and a method for forming the part are also disclosed. The method for forming the part includes arranging a plurality of cells (12) of the part and filling the gaps between the cells with the powder mixture (16). The disclosed powder mixture (16) has been tested and found to be highly efficient, provides passive cooling, and allows for a compact construction of the part. Easy processing of the powder mixture (16) allows for easy implementation of battery modules into various systems.

Description

[Technical Field]

[0001] The present disclosure relates generally to heat-dissipating powder mixtures and components having the powder mixtures. More particularly, the present disclosure relates to specially designed powder mixtures having both organic and inorganic components and components having the heat-dissipating powder mixtures. [Background technology]

[0002] In electronic and electrochemical devices, dissipation of generated heat is essential. Air and liquid cooling of automotive battery modules have been extensively studied to date. The primary purpose of cooling is to maintain the temperature of the battery module within a predetermined operating range. Heat accumulation in components such as battery modules usually leads to cell failure, which causes thermal runaway of the module. Air and liquid cooling require significant energy to circulate the coolant, including through fans and manifolds.

[0003] Another important aspect is the size of the battery pack. More sophisticated cooling systems generally result in larger components. US Patent No. 7,560,190 B2 discloses a cooling system for batteries that can alternately use both air and liquid as the cooling refrigerant. The overall idea of ​​the patent was to make the battery system combined with the cooling circuit easier to use and more compact. However, using air as the refrigerant makes the cooling method inefficient. While the use of liquid cooling was relatively successful, the use of auxiliary equipment such as pumps and fans prevented the system from being as compact as was desired.

[0004] Many battery packs are liquid-cooled, having a liquid such as oil or glycol that passes through the modules and uses convection to remove heat. However, as noted in U.S. Patent No. 9,774,065 B2, the cooling circuits are prone to leaks. At the same time, the need to cool and recirculate the liquid requires the use of peripheral equipment such as pumps and radiators, which consume a lot of space and power and are inefficient, as described in U.S. Patent No. 10,686,231 B2. In some cases, as shown in U.S. Patent No. 10,686,231 B, a liquid refrigerant is also used to enhance heat transfer, but the tight tolerances required for sealing pose manufacturing challenges and are not a cost-effective configuration.

[0005] Another approach is to use a phase change material (PCM) as a heat transfer element that can quickly remove the heat corresponding to the latent heat of the phase change, as described in patent US9312580B2. The PCM melts, absorbs the heat, and moves along a path that increases the surface area, allowing for better heat removal. Such technology can also use forced convection using fans, as shown in US8934235B2, but this also takes up extra space, generates noise, and consumes power. Furthermore, PCM materials exert stresses in all directions when they expand.

[0006] CN202010094027A provides an insulating material for suppressing thermal runaway diffusion in batteries. The material includes silicate aggregates filled with a thermally conductive material, water glass, a water repellent, a curing agent, an active filler, silica sol, a styrene-acrylic emulsion surfactant, a water glass reinforcing agent, reinforcing fibers, and a flame retardant. CN102040390B discloses a low-dimensional insulating material made of SiO2 nano / micron powder composites and one-dimensional aluminum silicate fibers that are uniformly dispersed and form a low-cost, high-temperature-resistant, low-thermal-conductivity low-dimensional insulating material. However, there remains a need for solid heat dissipation materials. Summary of the Invention

[0007] This Summary is provided to introduce a brief introduction to subject concepts that are further described in the Detailed Description of the Disclosure. It is not intended to identify key or essential inventive concepts of the subject matter, nor is it intended to delineate the scope of the disclosure.

[0008] To solve at least one of the above-mentioned problems, the present disclosure discloses a powder mixture that can effectively cool the heat-generating parts of any component, thereby preventing thermal runaway, explosion, and overload.

[0009] Briefly, in one aspect, a powder mixture for heat dissipation is disclosed. The powder mixture comprises C 15 H 24 The powder mixture includes two or more materials selected from the group consisting of carbonates, oxides, oxalates, and chlorides and one or more transition metal sources. Also disclosed is a part having the powder mixture.

[0010] In another aspect, a method for preparing a powder mixture for heat dissipation is disclosed. The method comprises: 15 H 24 The method includes dry-milling or dry-mixing two or more materials selected from the group consisting of carbonates, oxides, oxalates, and chlorides and one or more transition metal sources.

[0011] In yet another aspect, a method for forming a part having a plurality of cells is disclosed. The method includes arranging a plurality of cells in an apparatus and filling the gaps between the cells with a powder mixture. The powder mixture is adapted to dissipate heat. The powder mixture comprises a C 15 H 24 The catalyst includes two or more materials selected from the group consisting of carbonates, oxides, oxalates, and chlorides and one or more transition metal element sources.

[0012] The above summary is illustrative only and is not intended to be in any way limiting. In addition to the exemplary aspects, exemplary embodiments, and features described above, further aspects, exemplary embodiments, and features will become apparent by reference to the drawings and the following detailed description. [Brief explanation of the drawings]

[0013] These and other features, aspects, and advantages of the exemplary embodiments can be better understood from the following detailed description when read in conjunction with the accompanying drawings, in which like reference numerals refer to like parts throughout. [Figure 1A] FIG. 1A shows a schematic diagram of a battery module having a cylindrical cell arrangement and powder packing according to one embodiment of the present disclosure. [Figure 1B] FIG. 1B shows a top view of the cell and powder mixture arrangement in the battery module shown in FIG. 1A, according to one embodiment of the present disclosure. [Figure 1C] FIG. 1C shows a schematic diagram of a battery module with a pouch cell arrangement and powder filling according to one embodiment of the present disclosure. [Figure 1D] FIG. 1D shows a perspective view of a single cell in the battery module shown in FIG. 1C according to one embodiment of the present disclosure. [Figure 2] FIG. 2 is a comparative graph of the thermal performance of battery modules according to one embodiment of the present disclosure, comparing a battery module without heat sinking, a battery module with powder mix heat sinking, a battery module with powder mix and air cooling, and a battery module with liquid cooling, as measured using a particular type of cell with an allowable peak discharge of 20C. [Figure 3] FIG. 3 is a comparative graph of the thermal performance of battery modules, according to one embodiment of the present disclosure, comparing a battery module without heat sinking, a battery module with powder mix heat sinking, and a battery module with powder mix and air cooling, as measured using a particular type of cell with an allowable peak discharge of 4C. [Figure 4]FIG. 4 shows a graph comparing the thermal management performance of two types of powders as measured using a particular type of cell with an allowable peak discharge of 20C, according to one embodiment of the present disclosure. [Figure 5A] FIG. 5A is a graph illustrating the thermal management performance of a battery module having a powder mixture with specific percentages of specific components according to one embodiment of the present disclosure. [Figure 5B] FIG. 5B is a graph illustrating the thermal management performance of a battery module having the same components as the battery module having the thermal management graph shown in FIG. 5A, but with a powder mix having a different percentage ratio of the components according to one embodiment of the present disclosure. [Figure 6] Figure 6 is a graph of the thermal performance and comparison test of two battery modules tested under the same test setup and conditions, but with only one differentiator: a battery module with a powder mixture having C15H24 and a battery module without C15H24. DETAILED DESCRIPTION OF THE INVENTION

[0014] Additionally, those skilled in the art will appreciate that elements in the figures are illustrated for simplicity and have not necessarily been drawn to scale. Furthermore, with respect to the configuration of a device, one or more parts of the device may be represented in the figures by conventional symbols, and the figures may show only certain details relevant to an understanding of an embodiment of the invention so as not to obscure the figures with details that will be readily apparent to one skilled in the art having the benefit of the description herein.

[0015] For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same, it being understood that the scope of the invention is not intended to be limited thereby, and that such changes and further modifications in the illustrated systems, and such further applications of the principles of the invention as illustrated, are contemplated as would normally occur to one skilled in the art to which the invention pertains.

[0016] It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the invention, but are not intended to be restrictive thereof.

[0017] The terms "comprises," "comprising," or other variations thereof are intended to cover a non-exclusive inclusion, meaning that a process or method that includes a list of steps does not comprise only those steps, but may also include other steps not expressly listed or inherent in such process or method. Similarly, the phrase "comprises...a" or "comprises...a" does not, absent further constraints, exclude the presence of other devices, subsystems, elements, structures, or components, or additional devices, subsystems, elements, structures, or components. The appearances of "in one embodiment," "in another embodiment," and similar phrases throughout this specification do not necessarily all refer to the same embodiment.

[0018] The term DICO as used below refers to a mixture of various inorganic components and at least one organic component, namely C 15 H 24 and

[0019] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The systems, methods, and examples provided herein are illustrative only and are not intended to be limiting.

[0020] In addition to the exemplary aspects, embodiments, and features described above, further aspects and exemplary embodiments of the present disclosure will become apparent by reference to the drawings and the following detailed description.

[0021] The present disclosure relates to powder mixtures that can be used as effective heat dissipation materials when used in any heat-generating device, including electronic and electrochemical devices. Specifically, the disclosed powder mixtures are effective as heat dissipation materials in modular battery systems for electric vehicles, helping with cooling purposes and preventing thermal runaway, explosions, and thermal overload.

[0022] Convection and conduction are considered the dominant modes of heat transfer at and near room temperature. Conductive heat transfer is due to electron migration and molecular lattice vibrations. Battery module cells dissipate large amounts of heat to the powder during high loads and rapid cycling. The disclosed powders have a high absorption capacity to absorb the dissipated heat to maintain the cell's optimal temperature range. The disclosed powders store heat within their components and release it to an external heat sink.

[0023] This disclosure describes a synergistic powder mixture containing both organic and inorganic compounds, including, but not limited to, inorganic oxalates, chlorides, oxides, and carbonates. The powder mixture can be dry mixed, heated to drive off moisture, and used as a heat transfer medium. The disclosed powder mixture is suitable for both static and dynamic applications, including server grids and automotive cooling.

[0024] Specifically, the present disclosure discloses a powder mixture for heat dissipation. The powder mixture includes various components. C, an organic material, 15 H 24 is contained in the powder mixture. 15 H 24 belongs to the sesquiterpenoid family and is commonly known as isocaryophyllene, although other nomenclature may be used. 15 H 24 is a pale yellow oily liquid with a flash point slightly above 100°C. 15 H 24 It is used in the food and pharmaceutical industries due to its odor and anti-inflammatory properties.

[0025] As used herein, C 15H 24 is particularly advantageous for its low cloud point, high boiling point, high flash point, insolubility in water, and aromatic properties, and can be naturally sourced from essential oil-producing plants. When mixed with powdered inorganic compounds, it tends to increase the heat transfer rate of the resulting mixture, allowing for rapid heat dissipation.

[0026] The inorganic component of the powder mixture includes at least one carbonate, at least one oxide, and at least one oxalate. The inorganic component also includes two or more materials selected from the group consisting of chlorides and one or more transition metal element sources.

[0027] In some embodiments, the powder mixture includes two or more materials selected from the group consisting of calcium carbonate, silicon dioxide, neodymium praseodymium oxalate, and ammonium chloride, zirconium dioxide, zirconium sulfate, zirconium carbide, zirconium metal, iron oxide, and iron carbonyl. While calcium carbonate, silicon dioxide, and neodymium praseodymium oxalate are specifically mentioned herein, it should be noted that other carbonates, oxides, and oxalates may also be used in combination with these materials. Furthermore, other similar or dissimilar materials may be included in addition to the two or more selected materials to impart properties to the powder mixture depending on the application.

[0028] In some embodiments, the two or more selected materials include ammonium chloride along with one or more of zirconium dioxide, zirconium sulfate, zirconium carbide, metallic zirconium, iron oxide, and carbonyl iron. In certain embodiments, the two or more selected materials include two or more transition metal sources. In certain embodiments, the selected materials include ammonium chloride along with two or more transition metal sources. In various embodiments, the transition metal sources may include two zirconium sources, two iron sources, or at least one zirconium source and at least one iron source. In some embodiments, elemental forms of zirconium and carbonyl iron may be used.

[0029] The components of the powder mixture can have various weight ratios in the mixture. Generally, the components are15 H 24 ranges from 0.1 wt% to 30 wt% of the powder mixture, calcium carbonate ranges from 20 wt% to 60 wt%, silicon dioxide ranges from 5 wt% to 45 wt%, neodymium praseodymium oxalate ranges from 5 wt% to 25 wt%, and 2 or more The materials are mixed together in a range of 10 wt% to 65 wt%.

[0030] In some embodiments, the amounts of the two or more materials in the powder mixture may be such that ammonium chloride is present in a range of 0.1 wt% to 30 wt% of the powder mixture, and the one or more transition metal sources are present in a range of 10 wt% to 55 wt% of the powder mixture. The weight ratio of the transition metal sources may vary depending on the compound used as the transition metal source, but the above ranges can be considered to be approximately selected based on the amount of metal present in the compound used. Thus, in some embodiments, the amount of transition metal present in the one or more transition metal sources can be considered to be present in a range of 10 wt% to 55 wt% of the powder mixture. Depending on the application, the weight ratio of the powders can vary within the specific weight ranges described above.

[0031] To evaluate the thermal properties of the disclosed powder mixture, conductivity tests were performed on the powder mixture using the transient plane heat source (hot disk) method. In this method, a hot disk probe with negligible heat capacity is used to deliver stepwise heat pulses to generate a dynamic temperature field within the specimen. The probe also functions as a temperature sensor integrated with the heat source, i.e., a self-heating sensor. Test parameters, such as power output to the probe, probe radius, scan speed, and measurement time, depend on the material composition. The response, in terms of resistance change, is then analyzed using a model developed for the specific specimen, probe, and boundary conditions. A constant temperature (45°C) was maintained throughout the test. 45°C was chosen because it is the optimal temperature for the cell. The thermal conductivity of the disclosed powder mixture at 45°C is 0.284 W / mK, and the specific heat capacity is 1.096 MJ / m. 3It turned out to be K.

[0032] The present disclosure also discloses components having the disclosed powder mixtures. The disclosed powder mixtures can be used for thermal management of any component requiring heat dissipation. Specifically, the powder mixtures are particularly well-suited for components that have both a need for heat dissipation and space constraints. The powder mixtures can be used in electronic components such as microcontrollers, data servers, power electronics components, and the interior of motherboard cases for computing devices such as mobile phones, laptops, and HTPCs. The powder mixtures can also be used in electrochemical systems such as battery packs, battery modules, fuel cells, and electrolyzers. For example, the disclosed powder mixtures can be used in low-power range battery packs used in mobility applications such as motorcycles, scooters, hoverboards, and golf carts, as well as in backup power applications such as inverter battery packs and portable power modules for mobile phones and laptops. Various embodiments of the present disclosure are therefore described using the example of a battery module. However, it should be noted that the disclosed powder mixtures can be used for heat absorption and channeled heat dissipation to an external heat sink in any of the above-mentioned components and other components. Additionally, depending on the environment and application of the components and their operating conditions, the components and weight ratios of the powder mixture may be varied as disclosed above.

[0033] In some embodiments, the components disclosed herein are battery modules. Battery modules can be used individually or in combination with other modules in any application, including, but not limited to, automotive applications. A battery module includes multiple cells. The cells of a battery module can have different sizes, structures, and designs. For example, FIG. 1A shows a battery module 10 having cylindrically shaped cells 12, while FIG. 1C shows another battery module 10 having pouch-shaped cells 12. FIG. 1B shows a top view of the cell arrangement in the battery module 10 of FIG. 1A, and FIG. 1D shows a single cell 12 of the battery module shown in FIG. 1C. The cells 12 have cell walls 14, and in the battery module 10 of the present disclosure, the cell walls 14 are surrounded by a powder mixture 16. The powder mixture 16 surrounding the cell walls 14 cools the surfaces of each cell 12. The inherent heat absorption and heat dissipation properties of the powder mixture 16, along with the cell walls 14, facilitate heat absorption from the cells 12. The battery module 10 may further include a casing 18 that encases the plurality of cells.

[0034] The thermal management capability of a powder is evaluated by the heat dissipation provided by the powder in the system in which it is used for thermal management. In this example, the powder mixture (16) is placed around the cell in contact with the cell wall. The heat generated by the cell can vary depending on the application and operating conditions. Therefore, a standard has been devised to understand thermal management systems, compare performance, and aid in battery module design methods. kg / m 2 The metric, powder per cell area (MPCA), measured in units of 1 / 2, is used to evaluate the thermal management capability of the powder mixture (16). This metric is closely related to the surface area of ​​the cells (12) in contact with the powder mixture, since heat transfer from the cells (12) through the cell walls is dependent on the surface area of ​​the cells (12). Therefore, the MPCA of the battery module (10) can be determined as follows: TIFF0007774784000001.tif30128

[0035] It can be observed that a powder mixture 16 with a higher MPCA value is considered to have better performance in a given component 10. In some embodiments, the MPCA value of a battery module is 1 kg / m 2 ~12kg / m 2 In an exemplary battery module of the present disclosure, depending on the ingredients of the powder mixture (16), the resulting MPCA value is approximately 3.52 kg / m 2 Another example is the MPCA value of 6.589 kg / m 2 As a further example, the MPCA value obtained is 2.592 kg / m 2 These MPCA values ​​are considered to provide satisfactory performance for each battery module. 2 ~12kg / m 2 The range of 12 kg / m is desirable. 2 Beyond this, performance may become asymptotic and additional weight does not add much value.

[0036] The powder mixture used for cooling is intended to absorb heat from the cell surface and prevent cell temperature increases. The battery module casing can have gaps between cells, which act as pockets for filling powder along the cell surface, resulting in uniform heat distribution throughout the pack. The highly heat-absorbing powder maintains optimal cell temperatures. The powder mixture pockets also aid in thermal runaway, acting as fire suppressants to keep other cells safe if one cell overheats. Powder mixtures for surface cooling can also be used with other heat dissipation systems for axial cooling. Furthermore, air-cooling methods, such as natural or forced convection, can also be used in conjunction with the powder mixtures disclosed herein. In some embodiments of the present disclosure, both conductive and convective cooling methods are used to maintain battery cell temperatures within an operating range.

[0037] Pulse discharge tests were conducted on different battery modules with various cooling facilities to evaluate the thermal management performance of the disclosed powder mixture as a heat dissipation medium in the battery modules. The pulse discharge tests were conducted using a test cycle simulation of the driving conditions of a vehicle in which various battery modules are used. The battery modules are used under similar driving conditions. The simulated test conditions are extreme conditions in which a driver of a vehicle presses the accelerator for 4.5 seconds, releases the accelerator for 3.5 seconds, and repeats the acceleration and release cycle approximately 50 times. Therefore, the tests conducted here are based on T (on) The time is 4.5 seconds, T (off) This can be considered to have a duration of 3.5 seconds and a duty cycle of 55%.

[0038] The test cycle used here is one of the most stringent tests performed on cells. In this test, the cell is discharged from 100% state of charge (SoC) to 10% SoC in approximately 6 minutes. The ambient temperature during the test was maintained at 25°C. Proper thermal management during this test requires that the cell temperature not exceed 60°C, as this can shorten the cell's lifespan and lead to thermal runaway if not properly cooled.

[0039] Figure 2 shows a comparison graph of the thermal performance of four different battery modules. The cells used in the battery modules for this comparison are 26650 LiFePo4 type cylindrical cells, which have a high power density and allow a peak discharge of 20C.

[0040] In the battery modules compared, one battery module had no associated heat dissipation / cooling mechanism. Curve (22) in FIG. 2 represents the thermal performance of the battery module without a heat dissipation mechanism. Another battery module had a liquid cooling mechanism, and its thermal performance is represented by curve (24). Yet another battery module had a cooling mechanism using the powder mixture of the present disclosure, and its thermal performance is represented by curve (26). Yet another battery module had a heat dissipation mechanism using the powder mixture of the present disclosure in combination with air cooling, as represented by curve (28). The results clearly show that even under these extremely high power conditions, the cell temperatures of the battery module with only the powder mixture as a heat dissipation medium and the battery module with air cooling and the powder mixture as a heat dissipation medium did not exceed the operating limit of 60°C.

[0041] Figure 3 shows a comparison graph of the thermal performance of three different battery modules. The cells used in the battery modules for this comparison were 21700 Li-ion type cylindrical cells, which have a different power density than those shown in Figure 2, and the peak discharge allowed for the current cells is 4C.

[0042] Of the three battery modules, one battery module does not have a heat dissipation / cooling mechanism. Curve (32) represents the thermal performance of this battery module without powder. Another battery module has a cooling mechanism using the powder mixture of the present disclosure, represented by curve (34). Yet another battery module has a heat dissipation mechanism using the powder mixture of the present disclosure in combination with air cooling, represented by curve (36). The curves in the graph appear stepped because the minimum SoC count is 1 from 100 to 0, meaning that only one temperature data point can be displayed per SoC value of 1.

[0043] The curves in the graph represent a simulated test cycle for a vehicle using the battery module described above under similar driving conditions. The simulated test conditions are similar to those disclosed above. The test cycle used here discharges a complete cell from 100% SoC to 10% SoC in approximately 13 minutes. The ambient temperature during the test was maintained at 25°C. For proper thermal management, the cell temperature was not allowed to exceed 60°C during this test, as this can shorten the cell's lifespan and lead to thermal runaway if not properly cooled.

[0044] The results, shown graphically in Figure 3, clearly show that the battery module without any kind of cooling does not even reach a full cycle and reaches temperatures above 55°C. However, even at this very extreme high power condition, the cell temperature of the battery module with the powder mixture of the present disclosure remains at an optimum temperature of about 50°C, and the additional air cooling along with the heat dissipation using the powder mixture improves the thermal management of the battery module.

[0045] The powder mixture 16 is evenly distributed around each cell of the battery module 10, which helps minimize temperature gradients across the series and parallel connections of the cells 12 of the battery module 10. The powder mixture 16, through its conduction and high heat absorption capacity, prevents rapid heat buildup during deep discharge of the cells 12 of the battery module 10. The battery module 10 may also include various design features to prevent leakage of the powder mixture 16.

[0046] Figure 4 shows a graph comparing the thermal performance of two different battery modules with different powders. The curves in the graph represent a test cycle simulating automotive driving conditions. The simulated test conditions are similar to those disclosed above. In this test cycle, a complete cell is discharged from 100% SoC to 10% SoC in approximately 6 minutes. For proper thermal management, the cell temperature was not allowed to exceed 60°C, as this can shorten the cell's lifespan and lead to thermal runaway if not properly cooled.

[0047] A powder-packed cell was used to test the performance of two different powder mixtures. The peak discharge allowed for this cell was 20C. The two different powder mixtures had different powder components and ratios. The cell was operated separately using a baseline powder mixture and a powder mixture according to the present disclosure. The baseline mixture had a composition of calcium carbonate ranging from 40 wt% to 60 wt%, silicon dioxide ranging from 10 wt% to 40 wt%, and ammonium chloride ranging from 0.1 wt% to 10 wt%. The powder mixture disclosed in the present disclosure had a composition of calcium carbonate ranging from 20 wt% to 60 wt%, silicon dioxide ranging from 5 wt% to 45 wt%, ammonium chloride ranging from 0.1 wt% to 30 wt%, and ammonium chloride ranging from 0.1 wt% to 30 wt%. 15 H 24 , carbonyl iron powder in the range of 10 wt% to 30 wt%, neodymium praseodymium oxalate in the range of 5 wt% to 25 wt%, and zirconium metal powder in the range of 10 wt% to 35 wt%.

[0048] The graph in Figure 4 shows comparative test results for a cell with a baseline powder and a cell with a powder blend of the present disclosure when operated under the same test conditions. Specifically, in Figure 4, curve (42) shows the thermal performance of the cell when the baseline is used, and curve (44) represents the thermal performance of the cell when the powder composition as disclosed in the present disclosure is used.

[0049] The graph clearly shows that the disclosed powder mixes containing various disclosed components within specific ranges perform substantially better than the baseline powder containing only three components. Specifically, the graph shows that the baseline powder was unable to support the cell in completing the test, reaching 60°C after reaching 37% SoC, thereby not using the full capacity of the cell. However, the disclosed powder mixes were able to fully complete the test, keeping the cell within the optimal range by not allowing the cell to reach temperatures above 52°C. Thus, after rigorous testing of the powder samples, it can be seen that the disclosed powder mixes have superior performance.

[0050] Figures 5A and 5B show graphs of the thermal performance of battery modules with powder mixtures containing the same components but with different component ratios. The simulated test conditions are similar to those disclosed above. The test cycle involves discharging a complete cell from 100% SoC to 10% SoC in approximately 6 minutes. For proper thermal management, the cell temperature was not allowed to exceed 60°C in this test, as this could shorten the cell's lifespan and lead to thermal runaway if not properly cooled. A cell with a high powder density was used to test the performance of the two different powder mixtures. The peak discharge allowed for this cell was 20°C.

[0051] The two different powder mixtures have the same powder components but different component ratios. The powder mixture used in the first battery module is 25 wt% calcium carbonate, 50 wt% silicon dioxide, 1 wt% ammonium chloride, C 15 H 24 % of carbonyl iron powder, 2 wt% of neodymium praseodymium oxalate, and 18 wt% of metallic zirconium powder. Figure 5A shows a thermal management graph of a battery module with this composition.

[0052] The powder mixture used in the second battery module was 50 wt% calcium carbonate, 10 wt% silicon dioxide, 1 wt% ammonium chloride, C 15 H 24% of carbonyl iron powder, 2 wt% of neodymium praseodymium oxalate, and 12 wt% of metallic zirconium powder. Figure 5B shows a thermal management graph of the battery module with this composition.

[0053] Comparing the graphs in Figures 5A and 5B, it is clear that powder mixtures with the same ingredients but different ratios of ingredients have different thermal performance. Specifically, in the graph in Figure 5A, the test was not fully completed and stopped at 17% SoC because the temperature reached 60°C. In contrast, in the graph in Figure 5B, the test reached 60°C but was stopped at 10% SoC. Therefore, it is desirable to select the appropriate ratios of various ingredients in the powder mixture.

[0054] In some embodiments, C 15 H 24 is present in the range of 0.1 wt% to 14 wt% of the powder mixture, calcium carbonate is present in the range of 30 wt% to 55 wt%, silicon dioxide is present in the range of 10 wt% to 40 wt%, neodymium praseodymium oxalate is present in the range of 4 wt% to 12 wt%, and the two or more materials combined are present in the range of 20 wt% to 55 wt%. In some embodiments having ammonium chloride and both transition metal sources, the weight ratios of ammonium chloride and transition metal source used in certain applications are such that ammonium chloride is present in the range of 0.1 wt% to 11 wt% of the powder mixture, the elemental iron content in the iron source is present in the range of 1 wt% to 10 wt% of the powder mixture, and the zirconium metal content in the zirconium source is present in the range of 20 wt% to 35 wt% of the powder mixture.

[0055] Figure 6 shows the battery module, i.e., C 15 H 24 a battery module including a powder mixture having C 15 H 24This graph shows the thermal performance of a battery module with and without powder. Both battery modules were tested under the same test setup and conditions. Additionally, the amount of powder per cell remained the same for both battery modules during the test. The goal of the experiment was to discharge the battery pack from 100% to 10% within 6 minutes. The test involved a rigorous 20C high discharge on the 26650 cells.

[0056] In the experimental setup, as shown in the graph in Figure 6, DICO(60) is C 15 H 24 Powder 11 (61) represents a powder mixture containing all seven components, including C 15 H 24 Additionally, the test cycle includes simulating an extreme driving condition in which the driver presses the accelerator for 4.5 seconds, then releases it for 3.5 seconds, repeated approximately 50 times. The test duty cycle is T (on) In 4.5 seconds, T (off) The test cycle is the most severe test performed on a battery cell, discharging it from 100% SoC to 10% SoC in 6 minutes. The ambient temperature during the test is maintained at 25°C.

[0057] The graph in Figure 6 and the experimental results are 15 H 24 The battery module with DICO(60) containing all seven components showed good performance, reaching a temperature of 50°C. However, 15 H 24 The battery module using Powder 11 (61) without the additive failed the test because it reached the temperature threshold of 60°C at 14% SoC.

[0058] Therefore, C 15 H 24 It can be concluded that β plays an important role in heat dissipation and is an important part of the powder mixture (16) of the present invention for best results.

[0059] In one embodiment, a method for preparing a powder mixture (12) is provided. The method includes dry-milling or dry-mixing the components of the powder mixture. In some embodiments, the components may be heated before mixing / milling or after the mixing / milling step. Heating the components can remove moisture from the powder mixture. In some embodiments, heating is limited to 100°C.

[0060] In another embodiment, a method for forming a component having multiple cells, such as a battery module 10, is disclosed. The method includes arranging a plurality of cells 12 and filling the interstices between the cells with a powder mixture 16. Most or all of the cell walls are coated with the powder mixture 16, which aids in surface cooling and maintains low temperatures during high discharge cycles.

[0061] Thus, embodiments of the present invention provide a novel powder mixture that can be used for heat absorption purposes. This powder mixture can be used in any component that surrounds a heat-dissipating component to absorb heat from the component and dissipate it to an external heat sink. Testing of the disclosed powder mixture has shown it to be highly efficient, with a low MPCA value, allowing for compact component construction. The disclosed powder mixture is electrically non-conductive, providing high electrical insulation between component cells. The cooling method using the disclosed powder mixture is passive, meaning no moving parts or large equipment are required for cooling. The lack of moving parts eliminates component failure. The disclosed powder mixture also helps prevent thermal runaway and extinguish fires that may break out around the powder mixture.

[0062] The powder mixture facilitates modular design and allows greater flexibility in arranging battery modules in systems such as automobiles, allowing for more creative use of the space available within the vehicle. Additionally, the simple processing of the powder mixture allows for easy implementation of battery modules in a variety of systems.

[0063] While specific language has been used to describe the present disclosure, no limitations are intended thereby. Those skilled in the art will recognize that various practical modifications can be made to the present methods in order to implement the inventive concepts taught herein.

[0064] The figures and the foregoing description illustrate exemplary embodiments. Those skilled in the art will appreciate that one or more of the described elements may be combined into a single functional element. Alternatively, certain elements may be divided into multiple functional elements. Elements from one embodiment may be added to another embodiment. For example, the order of the steps described herein may be changed and is not limited to the aspects described herein. Furthermore, the actions in any flowchart need not be performed in the order shown, and not all actions necessarily need to be performed. Furthermore, actions that are independent of other actions may be performed in parallel with other actions. The scope of the embodiments is in no way limited by these specific examples. Numerous variations, such as differences in structure, dimensions, and use of materials, are possible, whether or not explicitly indicated herein.

Claims

1. A powder mixture (16) for heat dissipation, 0.1 wt% to 30 wt% C １５ H ２４ , 20 wt % to 60 wt % calcium carbonate, 5 wt % to 45 wt % silicon dioxide; 5 wt % to 25 wt % neodymium praseodymium oxalate, and 10 wt% to 65 wt% of two or more materials Contains a total of 100 wt% Two or more materials are (i) ammonium chloride from 0.1 wt % to 30 wt % of the powder mixture; (ii) 10 wt % to 55 wt % of the powder mixture of one or more transition metal sources selected from zirconium dioxide, zirconium sulfate, zirconium carbide, zirconium metal, iron oxide, and iron carbonyl; Including, C 15 H 24 is isocaryophyllene, powder mixture (16).

2. A part comprising the powder mixture (16) of claim 1.

3. 3. The component of claim 2, selected from the group consisting of a data server, a power distribution unit, and a computing device.

4. 3. The component of claim 2, The component is a battery module (10) comprising a plurality of cells (12); The powder mixture (16) is filled into the gaps between the cells (12) of the battery module; At least a portion of the cell wall (14) of the cell is covered with a powder mixture (16); The amount of powder mixture (16) per surface area of ​​the cells in contact with the powder mixture (16) is 1 kg / m 2 to 12 kg / m 2 .

5. A method for preparing a powder mixture (16) for heat dissipation, comprising: 0.1 wt% to 30 wt% C １５ H ２４ dry-grinding or dry-mixing two or more materials, 20 wt% to 60 wt% calcium carbonate, 5 wt% to 45 wt% silicon dioxide, 5 wt% to 25 wt% neodymium praseodymium oxalate, and 10 wt% to 65 wt%, totaling 100 wt%; the two or more materials comprising: (i) ammonium chloride in an amount of from 0.1 wt % to 30 wt % of the powder mixture; and (ii) one or more transition metal sources selected from zirconium dioxide, zirconium sulfate, zirconium carbide, zirconium metal, iron oxide, and iron carbonyl in an amount of from 10 wt % to 55 wt % of the powder mixture; The method wherein C 15 H 24 is isocaryophyllene.

6. A method for forming a part including a plurality of cells (12), comprising: arranging a plurality of cells (12); filling the gaps between the cells (12) with a powder mixture (16); Equipped with The powder mixture (16) is heat dissipating and contains 0.1 wt% to 30 wt% C. １５ H ２４ 20 wt% to 60 wt% calcium carbonate, 5 wt% to 45 wt% silicon dioxide, 5 wt% to 25 wt% neodymium praseodymium oxalate, and 10 wt% to 65 wt% of two or more materials totaling 100 wt%; the two or more materials comprising: (i) ammonium chloride in an amount of from 0.1 wt % to 30 wt % of the powder mixture; and (ii) one or more transition metal sources selected from zirconium dioxide, zirconium sulfate, zirconium carbide, zirconium metal, iron oxide, and iron carbonyl in an amount of from 10 wt % to 55 wt % of the powder mixture; The method wherein C 15 H 24 is isocaryophyllene.

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