Battery Pack Thermal Exchange Assembly With Phase Change Isolation
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Solution Overview
Problem
Thermal energy transfer between battery arrays in a battery pack can lead to increased thermal energy levels, causing venting gases and inefficient heat management, particularly during high temperature events like overcharging.
Innovation Solution
Incorporating a phase change material, such as sodium nitrite or potassium nitrite, secured to a thermal exchange device with an adhesive containing endothermic filler materials like sodium silicate, and utilizing thermal barriers to reduce thermal energy transfer between adjacent battery arrays, allowing the phase change material to absorb and dissipate excess heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If battery arrays are disposed adjacent to each other for compact packaging, then space utilization is improved, but thermal energy transfer between arrays increases causing overheating
Solution Approach 1:
A thermal exchange device is positioned between adjacent battery arrays to mediate thermal energy transfer. The device includes a phase change material that absorbs excess heat from one array and transfers it to coolant channels, preventing direct thermal coupling between arrays while maintaining compact packaging.
Solution Approach 2:
A phase change material is incorporated into the thermal exchange device to absorb thermal energy from battery arrays during high-temperature events. The material undergoes phase transition (e.g., solid to liquid) at a specific temperature range, providing passive thermal management and preventing thermal runaway propagation between adjacent arrays.
2Temperature
If thermal barriers are added to reduce heat transfer between arrays, then thermal management is improved, but device complexity increases
Solution Approach 1:
The thermal exchange device combines multiple functions into a single integrated component: it serves as both a thermal barrier between arrays and a heat dissipation system with coolant channels. The phase change material is incorporated directly into the device structure, eliminating the need for separate thermal management components.
Solution Approach 2:
The phase change material provides passive thermal management by automatically absorbing heat when temperature rises and releasing it when cooled by the liquid coolant. This self-regulating mechanism reduces the need for active control systems and complex thermal management electronics.
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
Effectively reduces thermal energy transfer between battery arrays, preventing overheating and venting, while allowing efficient heat dissipation through coolant channels, thereby enhancing the safety and performance of the battery pack.
Implementation Method 1
A phase change material is secured to an area of the thermal exchange device. The phase change material is configured to take on thermal energy from at least one of the battery arrays.
Implementation Method 2
the adhesive comprises an endothermic filler material
Implementation Method 3
the thermal exchange device includes liquid coolant channels that communicate a liquid coolant
Implementation Method 4
the thermal exchange device includes a thermal barrier that separates a first region of the thermal exchange device from a second region of the thermal exchange device
Data Source
AI summary
A traction battery assembly includes a thermal exchange device of a battery pack, and battery arrays disposed adjacent the thermal exchange device. A phase change material is secured to an area of the thermal exchange device. A method of managing thermal energy within a battery pack includes, among other things, positioning battery arrays against a thermal exchange device, and securing a phase change material to the thermal exchange device. The phase change material is configured to take on thermal energy from at least one of the battery arrays.