Battery Pack Corner Cooling Channels for Thermal Runaway Control
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Solution Overview
Problem
Existing battery packs face challenges in efficiently managing temperature fluctuations during charging and discharging, particularly during fast charging, which can lead to increased cell temperatures and potential thermal runaway.
Innovation Solution
A battery pack design featuring triangular cross-section cooling channels and thermal insulation materials between rows of prismatic battery cells, coupled with a HVAC system and charging station for controlled cooling and heating, to manage temperature gradients and provide mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling methods are used for battery packs, then cooling capability is limited, but temperature gradients increase and thermal runaway risk increases
Solution Approach 1:
The cooling system is segmented into multiple independent cooling channels positioned at different locations (top, bottom, and sides) of the battery pack. This segmentation allows different regions of the battery to be cooled independently, effectively reducing temperature gradients and preventing thermal runaway by addressing hot spots in specific areas rather than using a single centralized cooling approach.
Solution Approach 2:
The patent implements local cooling by positioning cooling channels specifically at the top and bottom of battery cells where heat generation and accumulation occur. The cooling capability is concentrated in these critical thermal zones rather than uniformly distributed, providing targeted thermal management where it is most needed to prevent thermal runaway.
2Volume of moving object
If triangular cross-section cooling channels are used, then packaging efficiency improves, but manufacturing complexity increases
Solution Approach 1:
The cooling channels are designed with curved triangular cross-sections rather than straight rectangular channels. This curvature allows the cooling channels to better conform to the cylindrical shape of battery cells, improving packaging efficiency by maximizing the use of available space. The curved design also provides structural strength while maintaining manufacturability through standard forming processes.
Solution Approach 2:
The cooling channels serve multiple functions: they provide thermal management by cooling battery cells, provide structural support to the battery pack, and optimize packaging efficiency. This multi-functionality reduces the need for separate structural components, simplifying manufacturing despite the complex triangular cross-section geometry.
3Reliability
If thermal insulation material is placed between battery cell rows, then thermal runaway protection improves, but heat dissipation efficiency may be reduced
Solution Approach 1:
Thermal insulation material is placed between adjacent battery cell rows to act as a thermal barrier. This intermediary layer prevents heat from propagating from one cell to adjacent cells, providing thermal runaway protection by isolating cells thermally while allowing the cooling system to maintain overall heat dissipation efficiency through the cooling channels.
Solution Approach 2:
The thermal insulation is applied locally between battery cell rows rather than throughout the entire battery pack. This localized insulation provides thermal runaway protection at the interfaces where heat propagation is most likely to occur, while maintaining heat dissipation efficiency in other regions through the cooling channels.
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 design effectively reduces cell temperature gradients, enables faster charging, enhances mechanical strength, and provides thermal runaway protection, improving packaging efficiency and reducing costs.
Implementation Method 1
a first cooling fluid channel that is configured to receive a cooling fluid... and a second cooling fluid channel that is configured to receive the cooling fluid
Implementation Method 2
a thermal interface material disposed between the battery cells and the cooling plate
Implementation Method 3
a thermal insulation material disposed at vertical bottoms of a linear space between the two linear rows of battery cells
Data Source
AI summary
A battery pack includes: prismatic battery cells arranged in two linear rows; a cooling plate disposed vertically below the battery cells; a thermal interface material disposed between the battery cells and the cooling plate; a thermal insulation material disposed at vertical bottoms of a linear space between the two linear rows of battery cells; a first cooling fluid channel that is configured to receive a cooling fluid, that extends linearly in the direction of the linear space, and that is disposed vertically above the thermal insulation material; and a second cooling fluid channel that is configured to receive the cooling fluid, that extends linearly in the direction of the linear space and parallel to the first cooling fluid channel, and that is disposed vertically above the thermal insulation material.