Battery Module Coolant Channel Pad for Thermal Runaway Containment
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Solution Overview
Problem
In air-cooled battery modules, thermal runaway phenomena can lead to rapid temperature increases and flame propagation due to inefficient coolant flow between unit modules, posing safety risks such as ignition and explosion, as existing structures hinder smooth coolant movement and often result in coolant leakage.
Innovation Solution
An air-cooled battery module design featuring a swelling absorption pad with a water coolant channel and an expansion pad that blocks air channels when coolant is introduced, ensuring smooth coolant flow and retention within the module to rapidly lower temperatures and prevent flame spread.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a pad is interposed between adjacent unit modules to absorb swelling, then the structural integrity and swelling absorption capability are improved, but the coolant flow between unit modules is blocked and cooling efficiency deteriorates
Solution Approach 1:
The pad is segmented into multiple regions: a first pad region in contact with battery cells for swelling absorption, and a second pad region forming a coolant channel for fluid flow. This segmentation allows the pad to simultaneously perform swelling absorption and coolant conduction functions without interference.
Solution Approach 2:
Different regions of the pad are assigned different functional qualities: the first pad region has high compressibility for swelling absorption, while the second pad region maintains coolant channel continuity for efficient heat dissipation. This local differentiation resolves the contradiction between swelling absorption and coolant flow.
2Temperature
If air channels are provided for air-cooled structure, then heat dissipation capability is improved, but coolant leakage occurs and cooling reliability deteriorates
Solution Approach 1:
The expansion pad provides dynamic response to thermal runaway conditions: under normal operation, air channels remain open for heat dissipation; when thermal runaway occurs and coolant is introduced, the expansion pad expands to close air channels and prevent coolant leakage, adapting to changing conditions.
Solution Approach 2:
The physical state of the expansion pad changes in response to coolant introduction: it transitions from a compressed state allowing air flow to an expanded state blocking coolant leakage paths. This parameter change enables the system to maintain both heat dissipation capability and coolant retention reliability.
3Loss of time
If coolant is introduced rapidly to lower temperature during thermal runaway, then flame propagation prevention is improved, but coolant flow resistance increases due to pad structure
Solution Approach 1:
The coolant channel is pre-formed within the pad structure during manufacturing, creating a ready-made flow path that eliminates the need for coolant to force its way through compressed pad material. This preliminary preparation reduces flow resistance and enables rapid coolant introduction during thermal runaway events.
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
The design effectively prevents flame propagation and quickly lowers temperatures within the battery module by ensuring smooth coolant flow and retention, thereby mitigating the risks of thermal runaway and associated safety hazards.
Implementation Method 1
a swelling absorption pad interposed between the unit modules adjacent to each other
Implementation Method 2
an expansion pad disposed inside the air inlet and the air outlet and configured to expand due to the contact with a water coolant introduced into the air-cooled battery module to close the air inlet and the air outlet
Implementation Method 3
a water coolant channel formed to extend along a longitudinal direction of the swelling absorption pad
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
Disclosed is a battery module, which includes a unit module stack formed by stacking a plurality of unit modules, each unit module having a plurality of battery cells stacked on each other; a swelling absorption pad interposed between the unit modules adjacent to each other; and a module housing configured to accommodate the unit module stack and the swelling absorption pad, wherein the swelling absorption pad has a coolant channel formed to extend along a longitudinal direction thereof.