Battery Pack With Dual-Case PCM Cooling And Thermal Cutoff

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Battery packs experience performance deterioration due to excessive temperature increases in the battery module, which existing technologies fail to effectively mitigate.

Innovation Solution

A battery case design incorporating an inner and outer case with a thin phase change material cooling member between them, and a cutoff mechanism that introduces the cooling member directly into the inner case when the battery cell exceeds a preset temperature, utilizing a shape-memory alloy expansion material to facilitate direct cooling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a traditional battery case structure is used, then the device is simple and easy to manufacture, but the battery module temperature increases significantly leading to performance deterioration

Engineering Contradiction:

Improvebattery module temperatureVSAvoidbattery case structure

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The battery case is divided into an inner case and an outer case, creating a dual-chamber structure. The inner case accommodates the battery module while the outer case provides structural support and houses the cooling member in the space between them, enabling effective thermal management through this segmented architecture

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A cooling member is introduced as an intermediary element positioned between the inner and outer cases. This cooling member actively manages heat transfer from the battery module through the inner case wall, serving as a thermal mediator that prevents excessive temperature buildup while maintaining the structural integrity of the battery pack

Inventive Principle:

Principle #24Intermediary (Mediator)

2Temperature

If the cooling member thickness is increased, then cooling performance is improved, but the battery case volume and weight increase

Engineering Contradiction:

Improvecooling efficiencyVSAvoidbattery case volume

Core Design Contradiction:

TemperatureVSVolume of stationary object

Solution Approach 1:

The cooling member is designed with an optimized thickness parameter that balances cooling effectiveness with space constraints. By carefully selecting the thickness within specific ranges, the design achieves sufficient thermal management performance while minimizing the volume occupied by the cooling system within the battery case structure

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The cooling member is positioned at specific locations where heat generation is most intense, such as near the battery module. This localized cooling approach concentrates cooling resources where they are most needed, achieving effective temperature control without requiring a uniformly thick cooling structure throughout the entire battery case

Inventive Principle:

Principle #3Local quality

3Reliability

If no active cooling mechanism is added, then the device remains simple, but the battery performance deteriorates at high temperatures

Engineering Contradiction:

Improvebattery performance stabilityVSAvoidcooling system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The cooling member is designed to passively absorb and dissipate heat from the battery module through thermal conduction and convection. The phase change material or cooling liquid in the cooling member automatically responds to temperature increases, providing self-regulating cooling without requiring external power sources or complex control systems

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The cooling member utilizes phase change materials that absorb large amounts of heat during phase transitions (such as melting or evaporation). This phase change mechanism provides highly effective cooling during critical temperature periods, maintaining battery performance stability without requiring continuous active cooling intervention

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 design effectively prevents temperature increases in the battery cell, improving performance and preventing potential explosions or ignitions by using indirect cooling with phase change materials and direct cooling through the cutoff mechanism.

Implementation Method 1

The cooling member may be provided as a phase change material (PCM)

Methodology Applied

Scientific EffectPhase change: Phase Change

Implementation Method 2

an expansion material disposed between the inner case and the outer case to press and cut the cutoff part while being expanded by high-temperature heat transferred from the battery cell

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS10454081B2Battery pack

Publication Date: 2019.10.22 LG ENERGY SOLUTION LTD

AI summary

A battery pack according to the present invention comprises a battery cell and a battery case accommodating the battery cell, wherein the battery case comprises an inner case accommodating the battery cell, an outer case disposed outside the inner case, and a cooling member between the inner and outer cases to indirectly cool the battery cell by using cool air generated by cooling the inner and outer cases.