Battery Cell PCM Layout for Thermal Gradient and Runaway Control
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Solution Overview
Problem
Battery systems experience uneven temperature gradients due to thermal management inefficiencies, leading to reduced performance and lifetime, and potential thermal runaway.
Innovation Solution
Incorporating a phase-changing material within the battery system that is in thermal contact with each cell and isolated from electric connection assemblies, expanding to absorb latent heat and manage thermal conduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If external thermal management methods are applied to the casing, then thermal management capability is improved, but effectiveness reduces due to poor radial conduction via internal air flow
Solution Approach 1:
The patent introduces a phase change material as an intermediary substance between the battery cells and the external thermal management system. This PCM acts as a thermal mediator that conducts heat radially from the battery cells more effectively than air, while still allowing the external thermal management system to function. The PCM fills the thermal conduction gap that exists in conventional air-cooled designs.
Solution Approach 2:
The patent utilizes the phase transition properties of the phase change material to manage thermal conduction. The PCM undergoes phase transitions (typically solid-liquid) at specific temperatures, absorbing or releasing latent heat during the process. This phase change mechanism enables the material to maintain effective thermal contact with battery cells across a range of operating temperatures, solving the poor radial conduction problem.
2Volume of moving object
If battery cells are spaced apart by gaps, then thermal expansion space is provided, but temperature gradients increase due to reduced thermal contact
Solution Approach 1:
The patent changes the thermal parameters of the gaps between battery cells by filling them with phase change material. Instead of leaving gaps as empty spaces or filling with air (poor thermal conductors), the PCM provides both the necessary expansion volume and improved thermal conduction. The material's thermal conductivity parameter is optimized to reduce temperature gradients while maintaining expansion capability.
Solution Approach 2:
The patent employs a composite approach by combining the structural function of gaps (providing expansion space) with the thermal management function of PCM. The phase change material creates a composite thermal management system that simultaneously addresses both the expansion space requirement and the temperature gradient reduction need, rather than treating these as separate problems.
3Temperature
If phase-changing material is in thermal contact with battery cells, then thermal management is enhanced, but risk of contact with electric connection assemblies increases
Solution Approach 1:
The patent applies segmentation by dividing the internal space of the battery pack into distinct functional zones. The PCM is confined to specific regions that are thermally coupled to battery cells but electrically isolated from connection assemblies. This spatial segmentation allows the PCM to perform thermal management functions while preventing harmful electrical contact, addressing both thermal management effectiveness and safety concerns.
Solution Approach 2:
The patent introduces structural intermediaries (such as insulating barriers or dedicated mounting structures) that mediate between the thermally active PCM and the electrically conductive connection assemblies. These intermediary elements allow thermal energy to be managed effectively while blocking the path for harmful electrical contact, thus preventing thermal runaway risks.
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 thermal management, prevents thermal runaway, improves performance and lifetime, and reduces operational costs by effectively managing temperature gradients.
Implementation Method 1
The phase-changing material is configured to expand when subjected to heat
Implementation Method 2
expanding to absorb latent heat and manage thermal conduction
Implementation Method 3
The phase-changing material is configured to expand when subjected to heat
Data Source
AI summary
A battery system includes a housing defining a plurality of walls. The battery system also includes a plurality of battery cells disposed in the housing. Each battery cell from the plurality of battery cells is spaced apart from an adjacent battery cell by a gap. Each of the plurality of battery cells includes any one of a prismatic battery cell and a pouch type battery cell. The battery system further includes at least one electric connection assembly connected to the plurality of battery cells. The battery system includes a phase-changing material disposed within the housing, such that the phase-changing material is in thermal contact with each of the plurality of battery cells and is isolated from the at least one electric connection assembly. The phase-changing material is configured to expand when subjected to heat.