Battery Module Cooling Triggered by Heat-Deforming Elements
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Solution Overview
Problem
Current thermal management systems (TMS) for Li-ion batteries are inadequate in handling rapid heat generation due to aging, harsh conditions, or failure, leading to thermal runaway and battery fires, with existing safety features being insufficient and costly.
Innovation Solution
A battery module with deformation elements made of bi-metals or shape memory alloys that deform at unsafe temperatures to direct coolant onto overheating cells, converting indirect to direct contact heat transfer for rapid cooling and preventing thermal runaway and fires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current thermal management systems are used to extract heat from batteries, then battery temperature is controlled under normal conditions, but the system cannot handle rapid heat generation during thermal runaway or abuse conditions
Solution Approach 1:
The system dynamically switches from indirect heat transfer (normal operation) to direct heat transfer (abnormal conditions) through deformation elements that respond to temperature changes. The deformation elements remain inactive during normal operation and only activate when batteries reach unsafe temperatures, allowing the system to adapt its cooling mechanism based on thermal conditions.
Solution Approach 2:
The deformation elements automatically activate the fire prevention mechanism when batteries reach unsafe temperatures without requiring external control. The system self-regulates by using temperature-sensitive materials that deform and open coolant tubes autonomously when thermal thresholds are exceeded.
2Reliability
If safety features are added to each cell, module, pack, and system, then battery safety is enhanced, but the cost increases and energy density decreases
Solution Approach 1:
The invention extracts the fire prevention function from complex multi-level safety systems and implements it through simple deformation elements and coolant tubes integrated into the thermal management system. This eliminates the need for redundant safety features at cell, module, pack, and system levels while maintaining comprehensive safety coverage.
Solution Approach 2:
The thermal management system performs dual functions: normal heat extraction during operation and fire prevention during thermal runaway. The same coolant tubes and deformation elements serve both thermal management and safety functions, eliminating the need for separate safety systems.
3Device complexity
If indirect contact heat transfer is used for cooling, then system simplicity is maintained, but cooling efficiency is insufficient during rapid heat generation
Solution Approach 1:
The heat transfer mechanism dynamically transitions from indirect to direct contact based on thermal conditions. During normal operation, indirect cooling suffices, but during abnormal conditions, deformation elements activate to enable direct coolant contact with battery surfaces, dramatically increasing cooling efficiency.
Solution Approach 2:
The system changes the heat transfer parameter from indirect to direct contact when batteries reach unsafe temperatures. This parameter change is triggered by deformation elements that respond to temperature changes, allowing the system to optimize heat transfer efficiency based on operational conditions.
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 system efficiently manages thermal flux, detects abnormal heating, prevents thermal runaway propagation, and extinguishes fires with minimal coolant usage, enhancing battery safety and efficiency while reducing costs and increasing energy density.
Implementation Method 1
a deformation element coupled to at least one of the one or more batteries and configured to deform if the at least one battery reaches an unsafe temperature
Implementation Method 2
direct coolant contact with the at least one battery
Data Source
AI summary
Systems and methods are described for thermal management, detection of abnormal cell heating, prevention of thermal runaway in the failing battery as well as the prevention of thermal runaway propagation and fire spread in battery systems. Battery systems and modules under the present disclosure can comprise deformation elements that deform when heated by a battery experiencing some type of failure. The deformation can be used to puncture a coolant tube, activate a nozzle, or otherwise release coolant onto the failing battery. The direct contact heat transfer, such as under boiling conditions, can quickly dissipate the heat using less coolant than prior art systems. Electrical circuits can automatically detect the deformation and disconnect the failing module or battery from a larger system.