Variable-Geometry Cooling Plates for Battery Thermal Runaway
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Solution Overview
Problem
Current battery pack designs for vehicles face challenges in efficiently managing thermal runaway events and optimizing electrical connections, which can lead to increased mass, volume, and interconnect resistance, while also requiring effective cooling and protection mechanisms.
Innovation Solution
The design incorporates cylindrical battery cells with customizable terminal orientations, electrically conductive busbars for efficient connections, a thermal runaway protection blanket to prevent heat transfer during thermal events, and a cooling plate with serpentine coolant channels and flow control valves to manage temperature effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If traditional battery pack designs are used, then manufacturing simplicity is maintained, but mass and volume increase due to less optimized interconnect structures
Solution Approach 1:
The patent combines the cooling plate and interconnect structure into a single integrated component. The cooling plate serves dual functions as both a thermal management system and an electrical interconnect, eliminating the need for separate interconnect components and reducing overall mass while maintaining manufacturing feasibility
Solution Approach 2:
The cooling plate is designed to perform multiple functions simultaneously: it provides thermal cooling through coolant channels, serves as an electrical interconnect between battery cells, and acts as a structural support element. This multi-functionality reduces the total number of components needed in the battery pack
2Temperature
If conventional cooling plate designs are used, then manufacturing simplicity is maintained, but thermal management effectiveness decreases due to inadequate coolant channel configuration
Solution Approach 1:
The coolant channel plate features varying channel geometries and configurations in different regions to match the local thermal requirements of battery cells. Channels are designed with different widths, depths, and patterns in areas experiencing higher versus lower heat generation, optimizing thermal management effectiveness
Solution Approach 2:
The cooling plate design incorporates adjustable flow control valves that allow dynamic regulation of coolant flow rates and distribution patterns. This enables the thermal management system to adapt to varying operational conditions and battery thermal states in real-time
3Adaptability or versatility
If battery cells with fixed terminal orientations are used, then manufacturing simplicity is maintained, but adaptability to different pack configurations decreases
Solution Approach 1:
The battery pack is designed as a modular system where cells can be arranged in different configurations (series, parallel, or combinations) within standardized housing modules. This segmentation allows flexible assembly configurations while maintaining manufacturing simplicity through standardized interfaces and mounting procedures
4Reliability
If thermal runaway protection mechanisms are added, then safety during thermal events is improved, but mass and volume increase
Solution Approach 1:
The thermal runaway protection blanket is integrated into the cooling plate structure, combining thermal protection functionality with the existing cooling and interconnect system. This integration provides thermal runaway protection without requiring separate protective components that would increase mass and volume
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 configuration enhances manufacturing efficiency, minimizes mass and volume, reduces interconnect resistance, and effectively manages thermal runaway events by isolating heat and ejecta, thereby improving the safety and performance of battery packs.
Implementation Method 1
a cooling plate including: a first planar plate; a second planar plate that faces the groups of two or more cylindrical battery cells; and a coolant channel plate that is sandwiched between the first and second planar plates
Implementation Method 2
a coolant channel that is fluidly connected to the inlet and the outlet and that extends in at least two different directions
Data Source
AI summary
A battery module includes: positive and negative terminals disposed on an exterior of a housing of the battery module; groups of two or more cylindrical battery cells, each of the battery cells of each group having positive and negative terminals; and electrically conductive busbars that electrically connect the groups, that electrically connect positive terminals of the battery cells of a first one of the groups with the positive terminal of the battery module, and that electrically connect negative terminals of the battery cells of a second one of the groups with the negative terminal of the battery module; and a cooling plate including: first and second second planar plates; and a coolant channel plate that is sandwiched between the first and second planar plates that includes: an inlet; an outlet; and a coolant channel that extends in at least two different directions.