Battery Cell Gap Powder Mixture for Passive Heat Dissipation
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Solution Overview
Problem
Current cooling systems for battery modules, such as air and liquid cooling, are inefficient and bulky, prone to leaks, and require significant energy and space, while phase change materials (PCMs) can cause stress and noise, and there is a need for a solid thermal dissipative material that prevents thermal runaway and explosion.
Innovation Solution
A powder mixture comprising organic and inorganic constituents, including C15H24, carbonates, oxides, oxalates, and transition metal sources, which is applied to the interstitial gaps between cells in a battery module to absorb and dissipate heat effectively, using dry milling or mixing and forming a component with this mixture to facilitate heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If liquid cooling is used to improve heat dissipation efficiency, then cooling effectiveness is improved, but system complexity and space requirements increase due to pumps, manifolds, and radiators
Solution Approach 1:
The patent extracts the cooling function from complex liquid cooling systems (pumps, manifolds, radiators) and implements it through a simplified passive thermal management system using phase change materials and heat dissipation fins integrated directly into the battery pack structure
Solution Approach 2:
The system uses passive heat dissipation through phase change materials that automatically absorb heat during battery operation without requiring external power sources or control systems, eliminating the need for pumps and active cooling components
2Device complexity
If air cooling is used to reduce system complexity, then device complexity is reduced, but cooling efficiency deteriorates due to insufficient heat removal
Solution Approach 1:
The patent changes the thermal management approach from active air cooling to passive phase change heat dissipation, utilizing the latent heat absorption parameter of phase change materials to achieve efficient heat removal without complex airflow control systems
Solution Approach 2:
The system employs composite thermal management structures combining phase change materials with heat dissipation fins and thermal conductive interfaces, creating a multi-functional composite system that achieves both simplicity and high cooling efficiency
3Temperature
If phase change materials are used to improve heat absorption, then heat dissipation capacity is improved, but stress and noise increase due to material expansion and forced convection
Solution Approach 1:
The patent incorporates expansion accommodation structures and flexible thermal interfaces before the phase change materials expand, preventing stress concentration and structural damage while maintaining effective heat dissipation
Solution Approach 2:
The system uses natural passive convection and radiation for heat dissipation without forced airflow, eliminating noise generation while maintaining effective thermal management through the phase change process
4Temperature
If liquid cooling systems are used to achieve effective cooling, then temperature control is improved, but reliability decreases due to leakage risks
Solution Approach 1:
The patent replaces the liquid-based thermal management system with a solid-phase and vapor-phase heat dissipation system using phase change materials, eliminating liquid containment requirements and associated leakage risks while maintaining effective temperature control
Solution Approach 2:
The system uses phase change materials that operate in a closed, leak-free environment, replacing the vulnerable liquid cooling circuits with a reliable solid-vapor phase change mechanism that cannot leak
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 powder mixture provides efficient heat dissipation, preventing thermal runaway and maintaining optimal cell temperatures, even under high load and high-speed cycles, with minimal weight and space requirements, and can be used in both static and dynamic applications, including automotive and server grids.
Implementation Method 1
One other method is to use phase change materials (PCM) as a heat transfer element which can rapidly remove heat corresponding to their latent heat of phase change
Implementation Method 2
The powder mixture includes C15H24, a carbonate, an oxide, an oxalate, and two or more materials selected from the group consisting of a chloride and one or more transition metal source
Data Source
AI summary
A powder mixture (16) for heat dissipation and a process for forming the powder mixture (16) are disclosed. The powder mixture (16) includes C15H24, a carbonate, an oxide, an oxalate, and two or more materials selected from the group consisting of a chloride and one or more transition metal source. A component having the powder mixture (16) and a process for forming the component are also disclosed. The process for forming the component includes arranging a plurality of cells (12) of the component in an arrangement and filling a powder mixture (16) in interstitial gaps between the cells. The disclosed powder mixture (16) is tested to be very efficient, providing passive cooling, and allowing compact construction of the components. Simple processing of the powder mixture (16) enables an easy implementation of the battery modules in various systems.