Vehicle Battery Pack PCM Brick Layout for Thermal and Voltage Safety
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current rechargeable battery packs for vehicles face challenges in thermal management and voltage regulation, particularly in high-voltage applications, which can lead to safety concerns and limitations in maintenance and operation.
Innovation Solution
The construction of a battery pack using phase change material blocks with integrated battery cells and connectors, arranged in series and parallel configurations, along with a manually operable interrupter assembly to manage voltage, ensuring safe operation within low-voltage limits when not in use, and efficient thermal dissipation through thermally conductive fillers and PCM blocks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high-voltage battery configurations are used to increase power output, then power delivery capability is improved, but safety risks and thermal management difficulties increase
Solution Approach 1:
The battery pack is divided into multiple modules, each module containing multiple bricks with series-connected cells. The modules can be connected in series for high-voltage operation or reconfigured for lower voltage, enabling power scaling while maintaining safety through modular isolation of thermal and electrical risks.
Solution Approach 2:
The system enables dynamic reconfiguration of voltage parameters by changing the series/parallel connection arrangement of modules. This allows the same hardware to operate at different voltage levels (high-voltage for power, low-voltage for safety), resolving the contradiction between power capability and safety.
2Reliability
If complex thermal management systems are added to prevent thermal runaway, then safety is improved, but device complexity increases
Solution Approach 1:
The PCM thermal management function is merged directly into the battery brick structure itself rather than being a separate system. The phase change material is positioned to直接接触 battery cells, providing passive thermal regulation without requiring external pumps, valves, or control systems.
Solution Approach 2:
The phase change material provides automatic thermal regulation through its inherent phase transition properties. When battery cells generate excess heat, the PCM absorbs it during phase change without requiring external control, enabling safety through self-regulating passive thermal management.
3Power
If battery modules are designed for high-voltage operation to improve power delivery, then power capability is improved, but maintenance safety and operational flexibility deteriorate
Solution Approach 1:
The battery system incorporates dynamic reconfiguration capability through interrupter assemblies that allow switching between series (high-voltage) and parallel (low-voltage) connections. This dynamic adaptability enables the same hardware to optimize for power delivery when needed or switch to safer low-voltage mode for maintenance and charging operations.
Solution Approach 2:
The battery modules are designed with universal connectivity that supports multiple operating modes (high-voltage power delivery, low-voltage safe operation, series and parallel configurations). This multi-functionality allows the system to adapt to different operational requirements without requiring separate hardware configurations.
4Device complexity
If passive thermal management using phase change material is used, then device complexity is reduced, but thermal management effectiveness may be insufficient for high-power applications
Solution Approach 1:
The thermal management system uses composite construction with phase change material integrated into the battery brick structure alongside thermally conductive elements. This composite approach enhances heat transfer effectiveness while maintaining the passive, simple system architecture, allowing the PCM to work synergistically with conductive pathways for improved thermal management.
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 configuration enhances thermal management, allows safe operation within low-voltage limits for maintenance, and maintains efficient power delivery while preventing thermal runaway, thus improving the safety and performance of vehicle battery packs.
Implementation Method 1
a phase change material block (62) having a plurality of slots (72) formed therethrough, each slot (72) receiving a corresponding one of the plurality of battery cells
Implementation Method 2
efficient thermal dissipation through thermally conductive fillers and PCM blocks
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A process for constructing a battery brick for a vehicle comprises: selecting a plurality of battery cells having a maximum charge temperature and having a maximum discharge temperature greater than the maximum charge temperature. A phase change material having a melting temperature lower than the maximum charge temperature of the plurality of cells is selected. Each battery cell of the plurality of battery cells is disposed at least in part in the phase change material, the phase change material being selected for dissipating at least a portion of heat generated upon activation of at least a portion of the plurality of battery cells.