Battery Module PCM Thermal Management

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Solution Overview

Problem

There is a need for improved battery systems in xEVs that enhance travel distance, performance, and reduce costs, particularly in integrating higher voltage batteries into traditional vehicle platforms without significant packaging modifications.

Innovation Solution

The integration of lithium ion battery modules with phase change materials (PCMs) that conduct and absorb heat, allowing for efficient thermal management and maintaining a uniform temperature profile, while conforming to the form factor of traditional lead acid batteries to facilitate easier retrofitting and improved functionality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If lithium ion battery modules are integrated into traditional vehicle platforms, then power performance and travel distance are improved, but packaging complexity and modification requirements increase

Engineering Contradiction:

Improvepower performanceVSAvoidpackaging complexity

Core Design Contradiction:

PowerVSDevice complexity

Solution Approach 1:

The battery module is designed to conform to the form factor of traditional lead acid batteries, allowing it to serve multiple functions: providing high voltage power for xEV applications while fitting into existing vehicle packaging designed for conventional batteries. This universal design approach enables the same physical space to accommodate different battery technologies across different vehicle platforms.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The invention changes key parameters of the battery module including its physical dimensions to match traditional battery form factors, voltage output to achieve higher power performance, and incorporates phase change materials to manage thermal characteristics. These parameter changes allow the battery to deliver improved power performance while maintaining compatibility with existing vehicle packaging.

Inventive Principle:

Principle #35Parameter changes

2Use of energy by moving object

If higher voltage lithium ion batteries are used, then travel distance and efficiency are improved, but thermal management challenges increase

Engineering Contradiction:

Improveenergy efficiencyVSAvoidthermal management

Core Design Contradiction:

Use of energy by moving objectVSTemperature

Solution Approach 1:

The battery module incorporates phase change materials (PCMs) that undergo phase transitions at specific temperatures. During charging and discharging cycles, the PCMs absorb and release thermal energy through phase changes, actively regulating the battery temperature and preventing thermal runaway, thereby managing the increased thermal challenges associated with higher voltage lithium ion batteries.

Inventive Principle:

Principle #36Phase transitions

Solution Approach 2:

The phase change materials act as intermediary substances between the battery cells and the external environment. They mediate the thermal management by absorbing excess heat generated during high-voltage operation and releasing it during phase transitions, protecting the battery from thermal stress while maintaining operational efficiency.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Volume of moving object

If battery module size is reduced to fit traditional platforms, then packaging compatibility is improved, but heat dissipation capability may be compromised

Engineering Contradiction:

Improvebattery module sizeVSAvoidheat dissipation

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

The phase change materials are integrated directly into the battery module structure at reduced dimensions. Despite the compact size, the PCMs provide sufficient thermal management capacity by utilizing phase transitions to absorb and dissipate heat, ensuring that heat dissipation capability is maintained even within the constrained volume of traditional battery form factors.

Inventive Principle:

Principle #36Phase transitions

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 solution extends the battery life, reduces capacity fade, and enhances power performance by effectively managing heat within the battery module, thereby improving the overall efficiency and cost-effectiveness of xEVs while maintaining compatibility with existing vehicle designs.

Implementation Method 1

The PCM is configured to conduct a first portion of the heat generated by the battery cell during operation

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Implementation Method 2

The PCM is configured to absorb a second portion of the heat generated by the battery cell to affect a phase change within at least a portion of the PCM

Methodology Applied

Scientific EffectPhase change: Phase Change

Data Source

PatentUS9312580B2Battery module with phase change material

Publication Date: 2016.04.12 CPS TECHNOLOGY HOLDINGS LLC

AI summary

In an embodiment, a system includes a battery module, a battery cell assembly that is a component of the battery module, and a battery cell of the battery cell assembly, wherein the battery cell is configured to generate heat during operation. The battery cell assembly also includes a phase change material (PCM) disposed along a thermal pathway within the battery cell assembly that transfers the heat generated by the battery cell away from the battery cell during operation. The PCM is configured to conduct a first portion of the heat generated by the battery cell during operation. Further, the PCM is configured to absorb a second portion of the heat generated by the battery cell to affect a phase change within at least a portion of the PCM.