A battery pack with an innovative heat management system via the integration of active and passive cooling components

Abstract

The invention relates to a battery pack which, by comprising both active cooling and passive cooling system components together and integrating them in a manner that allows them to operate simultaneously, is endowed with features of safety, efficiency, and long service life through optimal thermal management.

Description

[0001] A BATTERY PACK WITH AN INNOVATIVE HEAT MANAGEMENT SYSTEM VIA THE INTEGRATION OF ACTIVE AND PASSIVE COOLING COMPONENTS

[0002] TECHNICAL FIELD

[0003] The invention relates to a battery pack which, by comprising both active cooling and passive cooling system components together and integrating them in a manner that allows them to operate simultaneously, is endowed with features of safety, efficiency, and long service life through optimal thermal management.

[0004] PRIOR ART

[0005] A battery pack is a fully functional energy system formed by combining multiple battery cells for energy storage and management. In a battery pack, the battery cells are typically configured in series or parallel to achieve a specific voltage and capacity level. In addition, components such as the Battery Management System (BMS), cooling mechanisms, protective barriers, and other supporting elements are also part of the pack.

[0006] Battery packs are used in many fields where energy storage and management are critical. In electric vehicles, they power the motors, providing sustainable transportation solutions and serving as portable energy sources. In renewable energy systems, they ensure a continuous energy supply by storing energy generated from intermittent sources such as solar and wind. In applications such as portable electronic devices, laptops, and portable generators, they function as compact and efficient energy sources. Additionally, they are used in industrial energy storage systems and in commercial and off-grid energy solutions, contributing to energy savings and efficiency. In the aerospace industry, they offer lightweight and durable energy solutions, while in the defense industry, they are of critical importance as reliable energy sources for military vehicles and equipment.

[0007] Battery packs generate heat during energy storage and release processes due to chemical reactions. This heat can accumulate between the battery cells and, if left uncontrolled, may lead to overheating. Overheating not only reduces battery performance but can also result in dangerous situations such as thermal runaway. Cooling systems ensure that batteries operate at optimal temperatures, thereby enhancing the efficiency of chemical reactions and extending the service life of the batteries. Cooling systems are of critical importance for both safety and performance. Cooling systems in the current state of the art are generally based on either passive or active cooling methods, and these methods often fail to provide adequate thermal management. Passive cooling systems attempt to dissipate heat solely through natural convection; however, this can lead to temperature differences between battery cells. Active cooling systems distribute heat through liquid or air circulation, but these systems are typically effective only within limited temperature ranges. As a result, situations such as overheating or overcooling of the batteries may become uncontrollable.

[0008] On the other hand, active cooling systems particularly liquid- or air-based mechanisms continuously consume energy during operation, which reduces the overall energy efficiency of the battery system. This energy consumption by the cooling systems decreases the amount of usable energy that can be drawn from the battery, posing a significant problem especially in applications where energy efficiency is critical, such as portable devices or electric vehicles.

[0009] The cooling components in the current state of the art are generally not optimized in terms of mechanical durability. This creates problems particularly in applications exposed to vibrations, impacts, and environmental stresses, such as electric vehicles or portable energy solutions. Thermal protection components may not be designed to contribute to the long-term durability of the system.

[0010] The modular structure of battery packs has become a necessity with advancing technology due to advantages such as flexibility, scalability, and ease of maintenance. Modular battery packs offer customized solutions for various applications by allowing users to increase or decrease battery capacity according to their energy needs. Additionally, the ability to easily replace a faulty module prevents the entire system from becoming non-operational and reduces maintenance costs. However, cooling systems in the current state of the art are generally incompatible with modular structures. This poses a significant obstacle to the expandability of battery systems or their adaptation to different applications. Moreover, since cooling systems are not fully integrated with battery packs, temperature imbalances within each module cannot be adequately controlled. The most significant shortcomings of existing cooling systems include inadequate thermal management, low energy efficiency, issues with modularity and integration, inability to prevent thermal runaway risks, and weak structural durability. These deficiencies negatively impact the safety, performance, and longevity of battery systems. The most significant shortcomings of existing cooling systems include inadequate thermal management, low energy efficiency, issues related to modularity and integration, inability to prevent thermal runaway risks, and weak structural durability. These deficiencies adversely affect the safety, performance, and longevity of battery systems.

[0011] As a result, all of the aforementioned issues have made it necessary to introduce an innovation in the relevant technical field.

[0012] BRIEF DESCRIPTION OF THE INVENTION

[0013] The present invention relates to a battery pack configured with cooling systems, aimed at eliminating the above-mentioned disadvantages and bringing new advantages to the relevant technical field.

[0014] One objective of the invention is to prevent issues such as overheating, thermal runaway, and overcooling by integrating both passive and active cooling system components, and to provide a battery pack with effective thermal management.

[0015] Another objective of the invention is to present a battery pack capable of operating more efficiently by minimizing energy losses through the integration of passive and active cooling system components.

[0016] Another objective of the invention is to provide a battery pack in which, through the integration of passive and active cooling system components, operation within optimal temperature ranges is ensured and the stability of chemical processes is enhanced.

[0017] Another objective of the invention is to provide a battery pack with a modular configuration enabled by the integration of passive and active cooling system components.

[0018] BRIEF DESCRIPTION OF THE DRAWING

[0019] Figure 1 provides a schematic representation of battery packs featuring a liquid cooling system as the active cooling component.

[0020] In Figure 1 -Detail A, a representative view of a battery pack is provided. In Figure 1 -Detail B, a representative view of the layered structure of the passive cooling component surrounding the battery packs comprising PCM and heat-resistant barrier material is provided.

[0021] Figure 2 provides a representative view of battery packs that include a heater pad located on the outer part of the battery packs.

[0022] In Figure 2-Detail B, a representative view is provided showing the arrangement of the cooling components surrounding the battery packs, sequentially consisting of PCM, liquid cooling system, and heater pad.

[0023] BRIEF DESCRIPTION OF THE REFERENCES

[0024] 10 Battery Packs

[0025] 11 Phase Change Material (PCM)

[0026] 12 Liquid Cooling System

[0027] 13 Heat-Resistant Barrier Material

[0028] 14 Heater Pad

[0029] DETAILED DESCRIPTION OF THE INVENTION

[0030] In this detailed description, the invention relates to a battery pack (10) equipped with a cooling system that incorporates both active and passive cooling system components; it is explained solely through examples intended to facilitate a better understanding of the subject and does not have any limiting effect.

[0031] Referring to Figure 1 , the battery system is formed by the combination of multiple battery packs (10). As shown in Figure 1 -Detail A, the battery packs (10) consist of battery cells, which are the smallest units. A battery cell is the fundamental unit of the battery system where energy storage and conversion take place. It consists of components such as an anode, cathode, electrolyte, and separator, and it performs the process of converting chemical energy into electrical energy. Each cell possesses a specific voltage and capacity.

[0032] In the invention, the term "passive cooling system" refers to a system composed of components that provide thermal management through natural means without consuming energy. In this context, the invention employs phase change materials (11) and heat- resistant barrier materials (13) as components of the passive cooling system.

[0033] In the invention, the term "active cooling system" refers to a system composed of components that provide thermal management solutions by consuming energy. In this context, the invention employs a liquid cooling system (12) and heater pads (14) as components of the active cooling system.

[0034] Within the scope of the invention, cooling system components are first added around the battery cells. In Figure 1 , a liquid cooling system (12) is shown surrounding the battery packs (10). In this invention, the liquid cooling system (12) functions as an active cooling system component that effectively removes heat through liquid circulation in order to prevent overheating of the battery cells and to maintain thermal balance.

[0035] The liquid cooling system (12) includes liquid cooling pipes positioned around each battery cell. These liquid cooling pipes are placed around the battery cells and function as active cooling components that enable the effective removal of excess heat from the battery.

[0036] In a preferred embodiment, the liquid cooling system (12) includes at least one pump that ensures the continuous circulation of the fluid.

[0037] In a preferred embodiment, the liquid cooling system (12) includes at least one heat exchanger that enables the transfer of excess heat carried by the fluid from the battery cells to the ambient air or to another coolant.

[0038] In a preferred embodiment, the liquid cooling system (12) includes inlet and outlet sections through which the coolant enters and exits the system.

[0039] The liquid cooling pipes circulate fluid through them to transfer the heat absorbed from the battery cells to a heat exchanger, thereby ensuring that the batteries operate at an optimal temperature. These pipes perform rapid heat transfer, reducing the risk of thermal runaway and contributing to the safe and efficient operation of the batteries. Within the scope of this invention, the fluid may include at least one from the group consisting of water, glycol- based mixtures, thermal oils, or dielectric fluids.

[0040] The innovative aspect of the invention lies in the integration of passive cooling system components around the battery cells in addition to existing elements. Accordingly, a configuration containing passive cooling components is added around each battery cell. Figure 1 -Detail B provides a representative illustration of this configuration. According to this setup, the passive cooling system has a layered structure that includes a heat-resistant barrier material (13) positioned between the upper and lower layers.

[0041] As shown in Figure 1 -Detail B, the upper and lower layers contain one or more phase change materials (11), hereinafter abbreviated as PCM. Phase change materials (11) are thermal management materials capable of absorbing or releasing heat by transitioning between solid and liquid states within a specific temperature range. PCMs (11 ) have the capacity to store or release large amounts of latent heat during phase transitions, and through this property, they effectively manage temperature fluctuations. Within the scope of this invention, the PCM (11) may include at least one material selected from the group consisting of paraffin, fatty acids, hydrated salts, metals, graphene, carbon nanotubes, and aerogels.

[0042] As is known in the art, phase change materials (11) generally possess a soft or fluid structure, which limits their mechanical durability. To improve this characteristic, at least one support material is added to the phase change materials.

[0043] In a preferred embodiment, at least one of aluminum or its alloys is used as the support material. The use of aluminum-based components as a support material enables the mechanical stabilization of the PCM (11), thereby preventing issues such as leakage or deformation and enhancing the physical durability of the system. The use of aluminum as a support material offers effective technical solutions to both thermal and mechanical challenges in battery systems. Due to its high thermal conductivity, aluminum when used together with phase change materials ensures the rapid and uniform distribution of excess heat generated by the battery cells, thereby preventing thermal imbalances and overheating. Its lightweight structure allows it to provide support without increasing the overall weight of the battery system, while also offering protection against external impacts and thermal shocks.

[0044] The use of aluminum as a support material enables battery packs to have a modular structure thanks to its lightweight nature and thermal properties that provide effective heat management.

[0045] The passive cooling system surrounding the battery cells includes at least one heat- resistant barrier material (13) positioned between its upper and lower layers. In this invention, the heat-resistant barrier material (13) may comprise at least one material selected from the group consisting of quartz, graphite, silicon carbide (SiC), alumina (AI2O3), zirconia (ZrO2), tungsten, tantalum, molybdenum disulfide (MoS2), boron carbide (B4C), tantalum carbide (TaC), carbon fiber, titanium dioxide (TiO2), carbon nanotubes (CNT), Inconel alloys (e.g., Inconel 625), molybdenum, ceramic coatings, boron nitride (BN), hafnium carbide (HfC), ruthenium, nickel superalloys, titanium carbide (TiC), tungsten disulfide (WS2), nickel (Ni), platinum (Pt), sodium sulfate (Na2SO4) in stabilized form, nickel ferrite, magnesium oxide (MgO), sapphire (aluminum oxide), titanium alloys (e.g., Ti-6AI-4V), vanadium carbide (VC), boron (B), nitrided steel, zirconium oxide (ZrO2), tungsten carbide (WC), borosilicate glass (e.g., Pyrex), ceramic fibers, coated Kevlar, high- purity silicon, phosphor bronze, vanadium pentoxide (V2O5), hafnium, thermally carbonized wood (specially treated), corundum (sapphire), coated aramid fibers, ceramic matrix composites, cobalt superalloys, zinc oxide (ZnO), titanium silicon carbide (Ti3SiC2), magnesium aluminate spinel, silica aerogel, mica, asbestos, expanded vermiculite, kaolin, ceramic fiber insulation, fiberglass insulation, phenolic resin, epoxy resin, zirconium silicate (ZrSiO4), hydrogenated nitride ceramics, basalt fiber, expanded perlite, silica fiber fabric, graphite felt, pyrolytic carbon, magnesium hydroxide (Mg(OH)2), flame-retardant polymers, refractory bricks, and ceramic foams. In this invention, the heat-resistant barrier material functions as a thermal barrier material that ensures safety and durability by balancing both internal and external thermal effects around the battery cells. Due to its low thermal conductivity, it protects the battery cells against external temperature fluctuations and thermal shocks. At the same time, the chemical and mechanical stability of the heat- resistant barrier (13) allows it to form a reliable barrier between the phase change materials (11). During thermal expansion or contraction caused by the continuous phase changes of the PCM (11 ), the heat-resistant barrier remains stable against these physical changes and continues to perform its function without compromising the structural integrity of the system.

[0046] In Figure 2-Detail A, the liquid cooling system (12) is shown positioned adjacent to the layered structure that includes the PCM (11 ) and the heat-resistant barrier material (13). Additionally, as illustrated in Figure 2, a heater pad (14) is located further outward from the liquid cooling system (12), toward the outer side of the battery cells, and thus on the external part of the battery packs (10). The heater pad (14) is an active cooling component used in the battery system to maintain the optimal operating temperature of the battery packs (10) under low-temperature conditions. The heater pad (14) operates using electrical energy and directly heats the battery cells and consequently the battery pack (10) through resistive heating elements, ensuring the proper progress of chemical reactions. Heater pads (14) are typically positioned wrapped around the battery cells and, accordingly, on the outer surface of the battery pack (10). This arrangement improves the charging and discharging performance of batteries in cold ambient conditions and minimizes energy losses. By maintaining thermal balance under low-temperature scenarios, heater pads (14) enhance battery safety and extend service life. Moreover, they operate in conjunction with automatic control systems, activating only when needed, thus contributing to energy efficiency.

[0047] The heater pad (14) preferably includes at least one heating element. This heating element is the core component that converts electrical energy into thermal energy. Typically, wires or films that provide resistive heating are used as the heating element. The scope of protection of this invention is independent of the specific nature or type of the heating element used.

[0048] The heater pad (14) may include an insulation layer. This insulation layer can function as a thermal insulation component that ensures heat is directed as intended and that other components are protected from excessive heat. The scope of protection of this invention is independent of the specific nature or type of the insulation layer used.

[0049] The heater pad (14) may also include a protective coating. This protective coating can serve as an outer layer to ensure the heater pad’s (14) resistance to environmental factors. The scope of protection of this invention is independent of the specific nature or type of the protective coating used.

[0050] The heater pad (14) may include electrical connection points to supply the necessary energy for its operation.

[0051] The heater pad (14) may include one or more sensors. These sensors function to ensure temperature control and overall safety. Temperature sensors or thermostats may be utilized for this purpose.

[0052] In current applications, passive or active cooling systems in battery systems are generally used individually. In this invention, thermal management is initially achieved by integrating PCM (11), an aluminum support material, and a heat-resistant barrier material (13). The PCM materials (11) help optimize the temperature of the battery packs (10) by storing excess heat and releasing it when necessary, while the aluminum structure ensures efficient heat distribution by rapidly dispersing the heat. The heat-resistant barrier material (13) provides thermal insulation, thereby enhancing safety. This combination effectively manages the temperature balance around the battery cells, preventing thermal runaway and temperature fluctuations, and ensuring reliable and efficient battery operation. Additionally, active cooling system components are incorporated alongside this configuration as a further arrangement.

[0053] In current applications, cooling solutions or heater pads (14) in battery systems are generally used separately. In this invention, another proposed technical solution is the integration and co-location of the liquid cooling system (12) and heater pads (14). This combination enables fast and precise transitions between heating and cooling operations for the batteries. As a result, the thermal balance of the battery is maintained more consistently. The liquid cooling system (12) ensures the effective removal of excess heat generated by the battery cells, while the heater pads (14) support the operation of the batteries at optimal temperatures under cold environmental conditions.

[0054] In current applications, thermal regulation is typically limited to the surroundings or outer surfaces of the battery cells. In this invention, however, a two-way protection is achieved through the integration of thermal barriers and heating / cooling systems placed between the batteries. This configuration enables protection of the batteries against thermal stresses originating from both internal and external environments. The system minimizes heat transfer between battery cells, thereby preventing thermal shocks and ensuring more stable operation of the cells.

[0055] The scope of protection of the invention is defined in the claims provided in the annex and is by no means limited to the examples described in this detailed explanation. It is evident that a person skilled in the art may, in light of the above description and without departing from the main concept of the invention, develop similar configurations.

Claims

CLAIMS1. A battery pack (10) comprising a cooling system for controlling the heat generated by chemical reactions during energy storage and release processes to ensure optimal conditions, characterized in that the cooling system comprises:- a passive cooling system comprising a layered structure that surrounds each battery cell and includes at least one phase change material (11) as upper and lower layers, and at least one heat-resistant barrier material (13) positioned between said upper and lower layers,- an active cooling system comprising a liquid cooling system (12) positioned adjacent to the said layered structure and including components that ensure continuous circulation of fluid within, and a heater pad (14) positioned adjacent to the liquid cooling system (12) and located at the outermost part of the battery pack (10), used to maintain the optimal operating temperature of the batteries under low temperature conditions, characterized in that the battery pack (10) includes both the passive and active cooling systems together.

2. A battery pack (10) according to claim ^characterized in that the heat-resistant barrier material (13) comprises at least one material selected from the group consisting of quartz, graphite, silicon carbide, alumina, zirconia, tungsten, tantalum, molybdenum disulfide, boron carbide, tantalum carbide, carbon fiber, titanium dioxide, carbon nanotubes, Inconel alloys, molybdenum, ceramic coatings, boron nitride, hafnium carbide, ruthenium, nickel superalloys, titanium carbide, tungsten disulfide, nickel, platinum, sodium sulfate, nickel ferrite, magnesium oxide, sapphire, titanium alloys, vanadium carbide, boron, nitrided steel, zirconium oxide, tungsten carbide, borosilicate glass, ceramic fibers, Kevlar, high-purity silicon, phosphor bronze, vanadium pentoxide, hafnium, thermally carbonized wood, corundum, coated aramid fibers, ceramic matrix composites, cobalt superalloys, zinc oxide, titanium silicon carbide, magnesium aluminate spinel, silica aerogel, mica, asbestos, vermiculite, kaolin, ceramic fiber insulation, fiberglass insulation, phenolic resin, epoxy resin, zirconium silicate, hydrogenated nitride ceramics, basalt fiber, perlite, silica fiber fabric, graphite felt, pyrolytic carbon, magnesium hydroxide, flameretardant polymers, refractory bricks, and ceramic foams.

3. A battery pack (10) according to any of the preceding claims, characterized in that the phase change material (11) comprises at least one material selected from the group consisting of paraffin, fatty acids, hydrated salts, metals, graphene, carbon nanotubes, and aerogels.

4. A battery pack (10) according to any of the preceding claims, characterized in that the phase change material (11 ) includes at least one support material.

5. A battery pack (10) according to claim 4, characterized in that the support material comprises at least one of aluminum or an alloy thereof.

6. A battery pack (10) according to any of the preceding claims, characterized in that the liquid cooling system (12) comprises at least one cooling pipe and at least one pump.

7. A battery pack (10) according to any of the preceding claims, characterized in that the liquid cooling system (12) comprises, as the fluid, at least one selected from the group consisting of water, glycol-based mixtures, thermal oils, or dielectric fluids.

8. A battery pack (10) according to any of the preceding claims, characterized in that the heater pad (14) includes one or more sensors or thermostats.

9. A battery pack (10) according to any of the preceding claims, characterized in that the heater pad (14) comprises at least one component selected from the group consisting of at least one heating element, at least one insulation layer, or a protective coating.

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