Battery Cell Internal Cooling Structure for Large-Pack Heat Absorption

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Solution Overview

Problem

Existing rechargeable energy storage systems for vehicles face inefficiencies in heat mitigation, particularly with larger battery packs, as forced air systems and cold plates are not effective in absorbing large amounts of heat generated during charging and discharging.

Innovation Solution

A rechargeable energy storage system with an internal cooling structure that includes a housing with a coolant member and energy storage cells, where a heat absorption member extends through the energy storage medium, formed from thermally conductive materials coated with electrically insulative materials, and connected to a cooling fluid passage with a heat pipe or phase change material for enhanced heat transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If forced air convection systems are used to cool batteries, then cooling capability is provided, but heat absorption efficiency is insufficient for large battery packs

Engineering Contradiction:

Improveheat absorption efficiencyVSAvoidcooling capability

Core Design Contradiction:

TemperatureVSProductivity

Solution Approach 1:

The patent replaces forced air convection (mechanical fluid flow system) with direct thermal conduction through heat absorption members made of high thermal conductivity materials. This substitution eliminates reliance on air flow mechanics and achieves superior heat transfer through direct thermal contact between the cooling plate and battery cells.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The heat absorption members are constructed from composite or alloy materials with high thermal conductivity (such as aluminum alloys or copper-based materials), combining structural integrity with superior heat transfer properties to efficiently absorb heat from large battery packs.

Inventive Principle:

Principle #40Composite materials

2Temperature

If cold plates are used for cooling, then heat transfer is improved, but efficiency to absorb large amounts of heat is insufficient

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidheat absorption capacity

Core Design Contradiction:

TemperatureVSQuantity of substance

Solution Approach 1:

The cooling system is segmented into multiple independent heat absorption members, each equipped with its own heat pipe. This segmentation allows each unit to independently absorb heat from adjacent battery cells, collectively providing enhanced heat absorption capacity for large battery packs while maintaining efficient heat transfer at each local interface.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent incorporates heat pipes that utilize phase transition (evaporation and condensation of working fluid) to dramatically enhance heat transfer efficiency. The phase change process absorbs large amounts of latent heat, enabling the cold plate system to handle high heat loads from large battery packs effectively.

Inventive Principle:

Principle #36Phase transitions

3Temperature

If heat absorption members extend through energy storage medium, then thermal gradients are reduced, but electrical insulation requirements increase

Engineering Contradiction:

Improvethermal gradient reductionVSAvoidelectrical insulation complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent introduces thermal interface materials or coatings as intermediaries between the heat absorption members and battery cell surfaces. These intermediary layers enhance thermal contact while providing necessary electrical insulation, effectively decoupling the thermal and electrical function requirements.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 effectively reduces thermal gradients across energy storage cells, improving operational efficacy and extending the service life by efficiently absorbing and dissipating heat generated within the battery packs.

Implementation Method 1

A heat absorption member extends from the first end toward the second end through the amount of energy storage medium

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

a cooling fluid passage arranged between the first surface and the second surface, the cooling fluid passage including an inlet, an outlet

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

the coolant member including one of a heat pipe and a phase change material element that extends between the cooling fluid passage into the conduit

Methodology Applied

Scientific EffectPhase change: Phase Change

Data Source

PatentUS20240380025A1Rechargeable energy storage system including energy storage cells having an internal cooling structure

Publication Date: 2024.11.14 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A rechargeable energy storage system includes a housing including an interior zone, a coolant member arranged in the interior zone of the housing, and a plurality of energy storage cells arranged in the interior zone on the coolant member. Each of the plurality of energy storage cells includes a cell can defining an energy storage medium housing. The cell can includes a first end supported at the coolant member and a second end. An amount of energy storage medium is arranged in the energy storage medium housing. A heat absorption member extends from the first end toward the second end through the amount of energy storage medium.