Multi-Layer Battery Pack Heat Transfer Assembly for Thermal Runaway Prevention

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Solution Overview

Problem

Electrified vehicle battery packs face challenges in efficiently communicating and managing thermal energy, which can lead to thermal runaway conditions due to inadequate heat dissipation.

Innovation Solution

A battery pack assembly with a cell stack and thermal energy transfer assemblies, where copper sheets sandwiched with insulation layers transfer heat to a base sheet, which then communicates thermal energy to a coolant plate assembly, facilitating efficient heat removal through a liquid coolant system with staggered fins.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If thermal energy transfer assemblies are added between battery cells, then heat dissipation efficiency is improved, but device complexity increases

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoiddevice complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The thermal management system is segmented into multiple thermal energy transfer assemblies, each positioned between adjacent battery cells. Each assembly includes first and second sheets with an insulation layer sandwiched between them, creating modular units that collectively manage heat across the entire battery pack while maintaining manageable complexity through repetition of standardized components.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The thermal energy transfer assemblies are nested within the battery pack structure, with sheets positioned between battery cells and coolant plates. The multi-layered configuration of sheets and insulation layers creates a nested arrangement that maximizes thermal management efficiency within the available space without requiring external additions that would increase overall device complexity.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Temperature

If multi-layered thermal energy transfer assemblies are used, then thermal energy communication is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvethermal energy communicationVSAvoidmanufacturing complexity

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The thermal management system is divided into discrete thermal energy transfer assemblies that can be manufactured as standardized units. Each assembly consists of segmented layers (first sheet, insulation layer, second sheet) that can be produced separately and then assembled, allowing for specialized manufacturing processes for each layer while simplifying quality control and assembly procedures.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The thermal energy transfer assemblies utilize composite material structures with different layers serving specific functions: conductive sheets for heat transfer and insulating layers for thermal isolation. This composite approach allows each material to be optimized for its specific function while the overall assembly achieves superior thermal management performance, and the standardized composite units simplify manufacturing compared to custom-designed complex structures.

Inventive Principle:

Principle #40Composite materials

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 effectively manages thermal energy within the battery pack, preventing thermal runaway and ensuring efficient heat dissipation, thereby enhancing the safety and performance of electrified vehicle battery systems.

Implementation Method 1

each thermal energy transfer assembly including a first sheet and a second sheet that sandwich an insulation layer... communicating thermal energy from the first sheet and the second sheet to the coolant plate assembly

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

a first sheet and a second sheet that sandwich an insulation layer

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 3

communicating thermal energy from the base sheet to the coolant plate assembly... configured to communicate coolant between the first plate and the second plate

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS20230411726A1Battery pack with multi-layered thermal energy transfer assembly and thermal energy transfer method

Publication Date: 2023.12.21 FORD GLOBAL TECH LLC

AI summary

A battery pack assembly includes a cell stack having a plurality of battery cells distributed along an axis and a plurality of thermal energy transfer assemblies distributed along the axis. Each thermal energy transfer assembly is disposed between axially adjacent battery cells within the plurality of battery cells. Each thermal energy transfer assembly includes a first sheet and a second sheet that sandwich an insulation layer. The battery pack assembly further includes a coolant plate assembly and a base sheet sandwiched between the coolant plate assembly and the cell stack. The base sheet is configured to communicate thermal energy from the first sheet and the second sheet to the coolant plate assembly.