Battery Module Cooling Channels for Cell Tab Heat Isolation
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Solution Overview
Problem
Existing large-scale Li-ion battery systems face challenges in efficiently cooling and containing thermal runaway, particularly in marine and offshore applications, where weight, volume, and safety regulations are stringent, leading to potential degradation and reduced lifespan due to temperature variations and hotspots.
Innovation Solution
The use of electrically non-conductive, thermally conductive materials like polyamides or thermoplastics for cooling channels directly coupled to the cell tabs and both sides of the battery cells, combined with a cooling fluid, effectively transfers heat and prevents thermal runaway, while maintaining compactness and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If metal coolers are used for cooling energy storage devices, then cooling efficiency is improved, but electrical short circuit and leakage current issues occur between cooler walls and cell tabs
Solution Approach 1:
An electrically insulating layer is introduced between the metal cooler walls and the cell tabs to prevent direct electrical contact. This intermediary layer eliminates the risk of short circuits and leakage currents while maintaining the thermal coupling necessary for effective cooling of the energy storage devices.
Solution Approach 2:
The cooler structure is designed as a composite system combining metal materials for thermal conduction with electrically insulating materials for electrical isolation. This composite approach allows the cooler to simultaneously achieve high cooling efficiency through metal thermal conductivity while preventing electrical hazards through the insulating properties of the composite structure.
2Temperature
If complex cooling channel shapes are used to improve cooling performance, then temperature distribution is improved, but manufacturing difficulty increases
Solution Approach 1:
The cooling channel geometry is optimized by adjusting parameters such as channel cross-sectional area, wall thickness, and flow path length to achieve uniform temperature distribution across the energy storage device surfaces. These parameter changes enable effective cooling while maintaining manufacturability through standardized production processes.
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 approach enhances cooling efficiency, reduces weight and cost, extends battery lifespan, and ensures uniform temperature distribution, complying with safety and EMC requirements, thus improving the reliability and performance of energy storage systems.
Implementation Method 1
the cooler comprises a one or more enclosed cooling channels in contact with one surface of the energy storage device
Implementation Method 2
the cooling channels of the cooler comprise an electrically non-conducting material
Implementation Method 3
the cooler further comprises a section of the cooling channels thermally coupled to the protruding end of the cell tab
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
An energy storage system (1) comprises at least one energy storage module (10). Each module (10) comprises a plurality of energy storage devices (23). Each energy storage device comprises at least one electrically conducting cell tab (20, 21) electrically connected to electrodes of the energy storage device with one end of the cell tab protruding from the energy storage device. The energy storage module (10) further comprises a cooler (22) for each energy storage device, the cooler comprising a one or more enclosed cooling channels (25) in contact with one surface of the energy storage device. The cooler comprises an electrically non-conducting material. The cooler further comprises a section of the cooling channels thermally coupled to the protruding end of the cell tab (20, 21).