Battery Module Cooling Unit With Easy-to-Open Sealed Portion

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Solution Overview

Problem

Existing battery module cooling technologies lack a specific configuration for efficiently releasing coolant during abnormal heat generation, which can lead to overheating and chained heat events.

Innovation Solution

A cooling unit with a sealed portion that includes an easy-to-open portion, designed to release coolant when abnormal heat is generated, eliminating the need for temperature sensors and mechanisms to open the cooling unit, thereby preventing overheating of adjacent cells.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If cells are arranged close to each other to increase energy density, then the battery module can be downsized, but normal cells are exposed to high temperature when one cell abnormally generates heat

Engineering Contradiction:

Improveenergy densityVSAvoidheat exposure to normal cells

Core Design Contradiction:

Quantity of substanceVSObject-affected harmful factors

Solution Approach 1:

The sealed portion is divided into a hard-to-open portion and an easy-to-open portion. The easy-to-open portion is specifically designed to open at lower temperatures (e.g., using low-melting-point material or weaker sealing) to release coolant before the abnormal heat spreads to normal cells, while the hard-to-open portion remains sealed until higher temperatures are reached.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cooling unit is pre-filled with coolant and the sealed portion is designed in advance with differentiated opening characteristics. When abnormal heat generation is detected, the easy-to-open portion automatically opens first to release coolant onto the abnormal cell, preventing heat spread to adjacent normal cells before they are exposed to dangerous temperatures.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If a cooling tube is designed to partially melt to release coolant, then coolant can be released during abnormal heat generation, but the fabrication complexity increases

Engineering Contradiction:

Improvecoolant release capabilityVSAvoidfabrication complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The sealed portion is segmented into regions with different sealing strengths or material properties. The easy-to-open portion uses material or sealing conditions that allow it to open at lower temperatures or with less force, while the hard-to-open portion uses stronger material or sealing. This can be achieved by using different resin materials, different thicknesses, or different sealing pressures for different portions during fabrication.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the sealed portion have different local properties: the easy-to-open portion has lower melting point, lower sealing strength, or different material composition compared to the hard-to-open portion. This allows the sealed portion to exhibit non-uniform thermal response, opening at different temperatures based on the local properties of each portion.

Inventive Principle:

Principle #3Local quality

3Reliability

If temperature sensors and control mechanisms are added to manage abnormal heat generation, then overheating can be prevented, but the device complexity and cost increase

Engineering Contradiction:

Improveoverheating preventionVSAvoidtemperature sensing and control mechanisms

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The cooling unit is designed to automatically respond to abnormal heat generation without external control. The easy-to-open portion self-activates when exposed to abnormal heat, releasing coolant onto the abnormal cell. The system uses the thermal energy itself to trigger the cooling action, eliminating the need for external temperature sensors, control circuits, or power sources.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The abnormal heat generation, which is normally a harmful condition, is converted into the activation mechanism for the cooling unit. The heat from the abnormal cell directly causes the easy-to-open portion to open and release coolant, turning the harmful thermal energy into the driving force for the protective cooling action.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 solution improves productivity and prevents overheating of normal cells by quickly releasing coolant to the abnormal cell, enhancing energy density and reducing the risk of chained heat events without requiring additional temperature sensing or control mechanisms.

Implementation Method 1

the easy-to-open portion which is opened in the event of the abnormal heat generation

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

releasing a coolant... quickly releasing coolant to the abnormal cell

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS9293794B2Battery module

Publication Date: 2016.03.22 PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO LTD

AI summary

A cooling unit 20 is provided in the vicinity of a cell 10, and includes a sealed portion 22 formed by sealing a sheet 21. An easy-to-open portion 24 is provided in part of the sealed portion 22, and the easy-to-open portion 24 is opened when the cell 10 abnormally generates heat.