Battery Pack PCM Gap Fillers for Thermal Runaway Delay
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Solution Overview
Problem
Current battery pack cooling systems face challenges in enhancing performance due to low cooling efficiency, which can lead to heat accumulation, deterioration, and potential hazards like ignition or explosion in high-output and large-capacity battery modules used in electric vehicles and portable devices.
Innovation Solution
A battery pack design incorporating phase-change materials in gap fillers and compression pads to absorb and dissipate heat generated by battery cells, combined with a cooling apparatus structure that includes upper and lower cooling plates and busbar housings, effectively transferring heat and preventing abrupt temperature increases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional cooling structure with thermal interface material is used, then the battery pack can be manufactured with simple structure, but the cooling performance is insufficient leading to heat accumulation
Solution Approach 1:
The patent introduces phase change materials (PCM) in gap fillers and compression pads that undergo phase transition (solid-liquid) at specific temperatures to absorb excess heat from battery cells. This passive phase-change cooling mechanism significantly improves temperature control without requiring complex active cooling systems, directly resolving the contradiction between cooling performance and structural complexity
Solution Approach 2:
The patent uses composite structures combining conventional thermal interface materials with phase change materials in the gap fillers and compression pads. This composite approach integrates the thermal conductivity benefits of traditional materials with the high heat absorption capacity of PCM, achieving superior cooling performance while maintaining manufacturing simplicity
2Quantity of substance
If battery cells are concentrated in narrow space to increase capacity, then the energy density is improved, but heat dissipation becomes more difficult leading to higher temperatures
Solution Approach 1:
The patent applies phase change materials specifically in critical heat generation zones through gap fillers between cells and compression pads on cell surfaces. This localized application of thermal management functionality allows high cell density packing while providing targeted heat absorption at the most critical locations, resolving the contradiction between quantity and temperature control
3Power
If high-output and large-capacity battery modules are used, then the power output is increased, but the risk of heat-related hazards such as ignition or explosion increases
Solution Approach 1:
The patent incorporates phase change materials in advance within the battery module structure, creating a passive thermal buffer that activates automatically when temperature rises. This beforehand cushioning mechanism absorbs excess heat during normal operation and provides an additional safety barrier against thermal runaway, allowing high power output while improving reliability without complex safety systems
Solution Approach 2:
The phase change materials act as intermediary substances between battery cells and the external environment, providing an additional thermal management layer that mediates heat transfer. This intermediary PCM layer absorbs heat peaks and smooths temperature fluctuations, enhancing safety against thermal hazards while maintaining high power capability
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 use of phase-change materials in the battery pack enhances cooling efficiency, reducing the risk of heat-related issues and extending the time to reach maximum temperature during thermal runaway, thereby improving safety and performance.
Implementation Method 1
the upper and lower gap fillers may include a phase-change material
Implementation Method 2
The use of phase-change materials in the battery pack enhances cooling efficiency, reducing the risk of heat-related issues
Data Source
AI summary
An embodiment battery pack includes a battery module including a battery cell stack in which a plurality of battery cells are stacked in a predetermined direction, upper and lower cooling apparatuses disposed in upper and lower portions of the battery module, respectively, the upper and lower cooling apparatuses being configured to cool heat generated from the battery module, an upper cooling plate disposed between the battery module and the upper cooling apparatus, a lower cooling plate disposed between the battery module and the lower cooling apparatus, an upper gap filler filling a space between the battery cell stack and the upper cooling plate, and a lower gap filler filling a space between the battery cell stack and the lower cooling plate, wherein the upper and lower gap fillers each include a phase-change material.