Battery Pack Phase-Change Insulation for Thermal Runaway Control
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Solution Overview
Problem
Existing battery packs face inefficiencies in heat dissipation due to the high cost of phase change materials with low phase change temperatures and challenges in storing and contacting these materials effectively, which can affect safety and performance.
Innovation Solution
A battery pack design incorporating a thermal insulator with a working medium that changes phase from liquid to gas within an enclosed cavity, utilizing capillary channels and an isolation layer to enhance heat dissipation and safety, with a pressure-adjusted environment to optimize boiling point and prevent overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a phase change material with low phase change temperature is used to absorb heat from the battery pack, then heat dissipation capability is improved, but cost increases significantly
Solution Approach 1:
The patent changes the phase change temperature parameter of the working medium to match the operating temperature range of the battery pack. By adjusting this key parameter, the system achieves effective heat dissipation at battery operating temperatures without requiring expensive low-temperature phase change materials.
Solution Approach 2:
The working medium automatically absorbs heat through phase change when battery temperature rises, and releases heat when temperature drops, creating a self-regulating thermal management system that operates without external control or additional energy input.
2Ease of manufacture
If a phase change material with high phase change temperature is used, then cost is reduced, but heat dissipation efficiency decreases when battery temperature exceeds the phase change temperature
Solution Approach 1:
The patent selects and adjusts the phase change temperature parameter of the working medium to align with battery operating temperatures. This ensures the phase change occurs precisely when needed for heat dissipation, maintaining high efficiency while using cost-effective materials.
3Device complexity
If the phase change material is not properly stored and contacted with the battery pack, then structural complexity is reduced, but heat dissipation efficiency is seriously affected
Solution Approach 1:
The patent employs a porous thermal insulator material that serves dual functions: it provides thermal insulation and simultaneously acts as a reservoir to store the liquid working medium. The porous structure naturally wicks and distributes the working medium through capillary action, ensuring efficient thermal contact without complex delivery mechanisms.
Solution Approach 2:
The thermal insulator acts as an intermediary component between the battery pack and the working medium. It facilitates heat transfer from the battery to the working medium while maintaining proper storage and distribution of the phase change material, solving both insulation and heat dissipation requirements.
4Ease of operation
If the phase change material is used in an open environment, then ease of operation is improved, but safety performance deteriorates due to potential internal element damage from phase change
Solution Approach 1:
The patent creates a sealed enclosed cavity that isolates the working medium from the external environment. This sealed environment prevents contamination, maintains controlled pressure conditions, and protects internal battery elements from potential damage, while the system remains self-regulating and easy to operate.
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 improves heat dissipation efficiency and safety by effectively absorbing and dissipating heat through a dynamic vapor state—liquid state—vapor state cyclic phase change, preventing thermal runaway and ensuring the battery pack operates within safe temperature limits.
Implementation Method 1
the working medium changes a phase from a liquid state to a gaseous state to dissipate the heat from the multiple cell units
Implementation Method 2
heat from the battery pack is substantially absorbed through the phase change of a phase change material
Implementation Method 3
a thermal insulator disposed on the outer sides of the multiple cell units, where the interior of the thermal insulator is filled with a working medium for dissipating heat from the multiple cell units
Data Source
AI summary
A battery pack includes: multiple cell units; a housing forming an accommodating cavity for accommodating at least the multiple cell units, where the accommodating cavity is an enclosed space; and a thermal insulator disposed on the outer sides of the multiple cell units, where the interior of the thermal insulator is filled with a working medium for dissipating heat from the multiple cell units. When at least one of the multiple cell units reaches a preset temperature, the working medium changes a phase from a liquid state to a gaseous state to dissipate the heat from the multiple cell units.