Battery Package Cooling With Phase-Change Fire Mitigation
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Solution Overview
Problem
Current thermal management systems for large metal-ion battery packages, such as lithium-ion batteries in aircraft, are inadequate for reliable heat dissipation and fire safety, especially during thermal runaway failures, as external fire protection becomes difficult once fires form.
Innovation Solution
A thermal management system utilizing a conductive inter-cell separator between battery cells to transfer thermal energy to a coolant flow, which undergoes a phase change, and a condenser heat exchanger to dissipate heat, combined with suppressant nozzles for emergency coolant emission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If air cooling is used for battery packages, then the system is simple, but heat dissipation effectiveness is insufficient
Solution Approach 1:
The patent employs phase change material (PCM) that undergoes phase transition from solid to liquid at a specific temperature range (e.g., 20-40°C) to absorb large amounts of heat from battery cells during normal operation, providing efficient passive thermal management without complex active cooling systems
Solution Approach 2:
The thermal management system serves multiple functions: the PCM provides passive cooling during normal operation, while the same system integrates with fire suppression mechanisms that activate during thermal runaway, eliminating the need for separate cooling and fire protection systems
2Reliability
If external fire protection systems are installed, then fire safety is improved, but mitigation becomes difficult once fires form
Solution Approach 1:
Fire suppressant agents are pre-positioned within the battery package structure, and the system is designed to automatically activate these suppressants at the earliest signs of thermal runaway through temperature-sensitive mechanisms, preventing fire propagation before it becomes difficult to control
Solution Approach 2:
The patent introduces thermal barriers and fire-retardant materials as intermediary layers between battery cells that slow down thermal runaway propagation and provide time for suppression mechanisms to activate, making fire mitigation more effective
3Reliability
If thermal management system is enhanced for better heat dissipation, then reliability is improved, but system complexity increases
Solution Approach 1:
The thermal management system utilizes the battery's own operational characteristics to drive cooling: during charging/discharging, the system automatically activates cooling channels based on real-time temperature feedback from sensors, eliminating the need for complex external control systems
Solution Approach 2:
The patent combines thermal management channels with structural support elements and fire suppression pathways into a single integrated framework, where the same physical infrastructure serves multiple functions, reducing overall system complexity while maintaining high reliability
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 system effectively dissipates thermal energy and mitigates thermal runaway risks by efficiently cooling battery packages and providing fire suppression, enhancing both reliability and safety in aviation applications.
Implementation Method 1
Thermal energy is dissipated from the one or more battery packages via a phase change of the flow of coolant
Implementation Method 2
the flow of coolant changes phase from liquid to vapor phase in a range of 10 degrees to 45 degrees Celsius
Implementation Method 3
a condenser heat exchanger is fluidly connected to the flow of coolant to condense the flow of coolant to saturated liquid
Implementation Method 4
A thermal management system utilizing a conductive inter-cell separator between battery cells to transfer thermal energy to a coolant flow
Data Source
AI summary
A battery system of an aircraft includes one or more battery packages. Each battery package includes a plurality of battery cells. A thermal management system is fluidly connected to the one or more battery packages. The cooling system has a flow of coolant flowing therethrough. Thermal energy is dissipated from the one or more battery packages via a phase change of the flow of coolant. A method of managing thermal energy of a battery package includes conducting thermal energy from a plurality of battery cells via a conductive inter-cell separator located between adjacent battery cells, and transferring the thermal energy from the inter-cell separator to a flow of coolant in thermal communication with the conductive inter-cell separator, thereby causing a phase change in the flow of coolant resulting in cooling of the plurality of battery cells. The thermal energy is then dissipated from the flow of coolant.