Integrated Battery Cell Cooling and Support for Swelling Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery cells, particularly prismatic cells, face challenges with mechanical robustness, thermal management, and ease of maintenance due to issues such as mechanical stress, swelling, and overheating, which can damage internal components, and lack of efficient venting and electrical coupling configurations.
Innovation Solution
Incorporation of a center post for mechanical support, a cooling configuration with coolant lines, a thermally conductive potting material for thermal management, a removable side for maintenance, and improved electrical coupling and venting structures to address these issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a housing with reinforced sidewalls is used to protect against mechanical stress, then mechanical robustness is improved, but volume and mass increase
Solution Approach 1:
The center post is nested within the housing internal volume, providing mechanical support without requiring external reinforcement. The post fits inside the existing housing boundaries, delivering structural strength while maintaining compact dimensions.
Solution Approach 2:
Instead of reinforcing the housing sidewalls (surface dimension), the solution introduces a three-dimensional center post element that spans the internal volume. This dimensional shift from surface reinforcement to volumetric support provides mechanical robustness without increasing external housing dimensions.
2Strength
If a housing with reinforced sidewalls is used to protect against mechanical stress, then mechanical robustness is improved, but materials and mass increase
Solution Approach 1:
The center post is nested within the housing internal volume, providing mechanical support without requiring external reinforcement. The post fits inside the existing housing boundaries, delivering structural strength while maintaining compact dimensions.
Solution Approach 2:
The center post is constructed from composite materials that provide high strength-to-weight ratio, delivering mechanical robustness without proportionally increasing mass. The composite structure allows for optimized material usage that reduces overall weight compared to traditional metal reinforcement.
3Use of energy by moving object
If discrete energy units are used in the battery cell, then electrical energy storage is improved, but thermal management becomes more difficult
Solution Approach 1:
Thermally conductive potting material is introduced as an intermediary substance that fills the spaces between discrete energy units and connects them to the cooling structure. This material mediates heat transfer from multiple heat sources (energy units) to the cooling system, effectively managing thermal loads while preserving the electrical energy storage benefits of discrete units.
Solution Approach 2:
The thermal conductivity parameter of the surrounding material is changed by using thermally conductive potting material instead of conventional insulation. This parameter change enables efficient heat dissipation from discrete energy units while maintaining their electrical independence and energy storage capabilities.
4Temperature
If a cooling structure with coolant lines is added, then thermal management is improved, but device complexity increases
Solution Approach 1:
The cooling structure is merged with the housing and center post assembly, integrating thermal management functionality into existing structural elements. The coolant lines are routed through the center post and housing, combining mechanical support and thermal management functions in a single integrated design, thereby reducing overall device complexity.
Solution Approach 2:
The center post serves multiple functions: it provides mechanical support to the housing and simultaneously acts as a thermal conduction path and coolant line routing structure. This multi-functionality reduces the number of separate components needed, simplifying the overall device while improving thermal management.
5Temperature
If thermally conductive potting material is used, then thermal management is improved, but electrical insulation is reduced
Solution Approach 1:
The potting material is applied locally in specific regions where thermal conduction is needed, rather than uniformly throughout the entire battery cell. This localized application allows thermally conductive material to be used near cooling structures while maintaining electrical insulation in other critical areas through conventional insulating materials or design features.
Solution Approach 2:
The thermally conductive potting material serves as a thermal intermediary between energy units and cooling structures, while separate electrical insulation barriers are maintained in critical areas. The system uses the potting material's thermal properties where needed while preserving electrical isolation through design features such as insulated barriers or spacing.
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
Enhances mechanical robustness, thermal stability, and facilitates easy maintenance while ensuring efficient electrical and thermal management, thereby protecting the battery cell from mechanical stress and overheating.
Implementation Method 1
a cooling structure thermally coupled to a plurality of energy units
Implementation Method 2
a thermally conductive potting material for mechanical and thermal support of the battery cells
Data Source
AI summary
In accordance with some embodiments of the present disclosure, a battery cell includes a housing including at least one inlet port and at least one outlet port, at least one coolant line extending between the at least one inlet port and the at least one outlet port, at least one energy unit arranged within the housing, and a cooling structure coupled to the at least one coolant line, wherein the cooling structure is thermally coupled to the at least one energy unit. In some embodiments, respective ends of the coolant line include respective sockets, each configured to couple to one of the at least one inlet port and the at least one outlet port. In some embodiments, at least one of the sockets is configured to mate with a cooling line of an additional battery cell.