Battery Module Cooling Unit with Thermal Vulnerable Section

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Solution Overview

Problem

Existing battery module cooling units are inefficient in rapidly cooling abnormal cells during heat generation, and they often require complex temperature sensing and unsealing mechanisms, which increases the size and complexity of the battery module.

Innovation Solution

A cooling unit with a vulnerable section of low compressive strength is placed between cells, which unseals and releases a cooling agent when abnormal heat generation occurs, allowing for direct cooling of the affected cell without the need for temperature sensors or complex unsealing mechanisms, thereby improving cooling efficiency and reducing module size.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a cooling unit with complex temperature sensing and unsealing mechanisms is used, then the cooling control precision is improved, but the device complexity and module size increase

Engineering Contradiction:

Improvecooling control precisionVSAvoidmodule complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The cooling unit employs a vulnerable section that automatically unseals in response to abnormal heat generation without requiring external temperature sensors or control systems. The cooling agent is released automatically when the vulnerable section fails under thermal stress, enabling the system to self-regulate cooling based on thermal conditions

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces complex mechanical temperature sensing and controlled unsealing mechanisms with a passive thermal-mechanical response system. The vulnerable section's compressive strength decreases with temperature, causing automatic unsealing through material property changes rather than mechanical actuation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Volume of moving object

If cells are arranged in intimate proximity to increase energy density, then the volume efficiency is improved, but the heat spread risk worsens

Engineering Contradiction:

Improvebattery module sizeVSAvoidheat spread risk

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

The cooling unit is positioned between adjacent cells as an intermediary structure. It contains a cooling agent that can be rapidly released to cool abnormal cells, acting as a protective mediator that prevents heat propagation while allowing the cells to maintain intimate proximity for high energy density

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The cooling unit is pre-positioned between cells with cooling agent ready for release. The vulnerable section is designed to fail at specific thermal conditions, providing beforehand protection against heat spread before abnormal heat generation can propagate to neighboring cells

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Reliability

If existing cooling units are used, then the cooling function is provided, but the cooling speed is insufficient

Engineering Contradiction:

Improvecooling functionVSAvoidcooling speed

Core Design Contradiction:

ReliabilityVSSpeed

Solution Approach 1:

The cooling unit is pre-filled with cooling agent and the vulnerable section is pre-configured to fail at specific thermal conditions. When abnormal heat generation occurs, the vulnerable section rapidly unseals, allowing immediate release of the cooling agent directly onto the abnormal cell, achieving rapid cooling without delay from activation mechanisms

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The cooling unit transitions from a sealed static state to an unsealed dynamic state when thermal conditions require cooling. The vulnerable section's compressive strength dynamically decreases with temperature, enabling the system to adapt its cooling capability based on real-time thermal conditions

Inventive Principle:

Principle #15Dynamics

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 enables rapid cooling of abnormal cells, prevents chain reactions of heat generation, and simplifies the battery module design by eliminating the need for temperature sensors and unsealing mechanisms, while maintaining high energy density and flexibility in mounting.

Implementation Method 1

When heat is abnormally generated in at least one of the cells, the vulnerable section is unsealed

Methodology Applied

Scientific EffectThermal softening: Melting

Data Source

PatentUS8846235B2Battery module

Publication Date: 2014.09.30 PANASONIC HOLDINGS CORP

AI summary

A battery module including: a plurality of aligned cells, wherein a cooling unit accommodating a cooling agent is provided in a vicinity of the cells, part of the cooling unit is a vulnerable section having a relatively low compressive strength, and the vulnerable section is unsealed when heat is abnormally generated in at least one of the cells.