Air Plenum Cooling for Battery Cell Thermal Runaway
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Larger battery cell packages face challenges in cooling and containment due to the limitations of conduction and natural convection, which can lead to thermal runaway and increased safety risks, while liquid cooling systems require extra space and add complexity.
Innovation Solution
The implementation of a forced air cooling system using an air plenum assembly with a cooling plenum and exhaust plenum, coupled with thermal separators made of non-conductive, high melting point materials, to efficiently dissipate heat and contain individual battery cells, preventing thermal runaway propagation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conduction and natural convection cooling methods are used for larger battery cell packages, then the cooling system is simple, but the cooling effectiveness is insufficient leading to thermal runaway risks
Solution Approach 1:
The patent implements a forced air cooling system using plenums (air channels) that distribute cooled air to battery cells. The system uses air flow (pneumatics) to actively remove heat from battery cells, with inlet plenums delivering cool air and outlet plenums exhausting heated air, thereby improving cooling effectiveness and thermal safety without requiring complex liquid cooling infrastructure
Solution Approach 2:
The cooling system is divided into separate functional segments: inlet plenums for delivering cooled air, outlet plenums for exhausting heated air, and individual battery cell compartments. This segmentation allows optimized air flow paths and independent control of cooling zones, improving overall cooling effectiveness while maintaining system simplicity
2Reliability
If liquid cooling systems are implemented for larger battery cell packages, then cooling effectiveness is improved, but space requirements increase and manufacturing complexity increases
Solution Approach 1:
The patent replaces liquid cooling systems with a forced air cooling system using plenums. Air is circulated through the battery pack via inlet and outlet plenums, providing effective heat removal without the complexity of liquid coolant loops, pumps, and heat exchangers. This pneumatic approach maintains thermal safety while reducing manufacturing complexity
Solution Approach 2:
The patent extracts the cooling function from complex liquid cooling infrastructure and implements it through simplified air-based plenum structures. By taking out the need for liquid coolant systems and replacing them with air flow channels, the patent reduces both space requirements and manufacturing complexity while maintaining effective cooling
3Reliability
If thermal separators with high melting point materials are used, then thermal runaway propagation is prevented, but manufacturing complexity increases
Solution Approach 1:
The patent divides the battery pack into individual cell compartments separated by thermal separators. Each separator is designed as a simple partition with specific thermal properties (high melting point materials like ceramic or aluminum oxide), creating physical barriers that prevent thermal runaway propagation. This segmentation approach provides effective containment while maintaining manufacturing simplicity through modular assembly
Solution Approach 2:
The thermal separators are strategically positioned between individual battery cells where thermal runaway containment is most critical. The separators have localized high melting point properties specifically at the interfaces between cells, providing targeted thermal protection without requiring the entire battery pack structure to be made of complex high-performance materials
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution provides effective cooling with reduced space requirements and manufacturing complexity, maintaining safety by preventing thermal runaway propagation and reducing the risk of fire, while being more cost-effective than liquid cooling systems.
Implementation Method 1
The implementation of a forced air cooling system using an air plenum assembly with a cooling plenum and exhaust plenum, coupled with thermal separators made of non-conductive, high melting point materials, to efficiently dissipate heat
Implementation Method 2
a first aperture located on a third side of the first plenum for directing air from the inlet at the first side of the first plenum to a first compartment, wherein the first compartment includes a first battery cell
Data Source
AI summary
An air plenum assembly includes a first plenum for cooling, where the first plenum includes an inlet for air intake located at a first side of the first plenum. The air plenum assembly further includes a second plenum for exhausting heated air, where the second plenum includes an outlet for exhausting air located at a first side of the second plenum. The air plenum assembly further includes a first aperture located on a first side of the first plenum for directing air from the inlet at the first side of the first plenum to a first compartment and includes a first vent located on a first side of the second plenum for exhausting air away from the first compartment towards the outlet at the first side of the second plenum. The first compartment is isolated from surrounding battery compartments by at least two thermal separators.