Phase Change Composite Spacers for Battery Pack Thermal Control
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Solution Overview
Problem
Current lithium-ion battery packs face challenges in effective temperature regulation, as existing phase change materials and composites do not provide sufficient thermal management, leading to inefficiencies in energy storage and performance.
Innovation Solution
The development of a method to create improved phase change composites by impregnating a matrix material, such as graphite, with phase change materials like paraffin or wax, fragmenting it, and shaping it into specific forms for use between battery cells, including spacers with open-faced battery seats, to enhance thermal management and flexibility in battery pack design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If phase change materials are used for temperature regulation in battery packs, then thermal management is improved, but mechanical strength is insufficient
Solution Approach 1:
The patent combines phase change materials (paraffin, wax, hydrated salts, fatty acids, or hydrogenated bio-oils) with matrix materials (graphite, metal foams, or ceramic foams) to create composite structures. This composite approach allows the material to simultaneously provide thermal management through phase change and mechanical support through the matrix structure, resolving the contradiction between temperature regulation capability and mechanical strength.
2Strength
If phase change materials are encapsulated in matrix materials, then structural support is improved, but wax leakage occurs
Solution Approach 1:
The patent utilizes porous matrix materials such as metal foams and ceramic foams with controlled pore structures. These porous structures provide structural support while the pore architecture and surface properties prevent wax leakage through capillary action and physical confinement, allowing the phase change material to remain contained within the matrix structure during thermal cycling.
3Temperature
If conventional PCC blocks are used, then thermal management is provided, but design flexibility is limited
Solution Approach 1:
The patent divides the phase change composite into modular components including spacers with integrated battery seats, individual cell holders, and customizable geometric configurations. This segmentation allows the thermal management system to be adapted to different battery pack layouts, cell types (pouch, prismatic, cylindrical), and spatial requirements, significantly improving design flexibility while maintaining thermal management functionality.
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 approach provides enhanced thermal regulation, improved mechanical strength, and flexibility in composite shapes, allowing for better temperature control and performance in battery packs, while maintaining acceptable mechanical properties and reducing wax leakage.
Implementation Method 1
the use of phases change materials, such as wax, are used to store and release heat
Implementation Method 2
phase change materials are known to be supported by matrix materials, such as an encapsulated wax material in a graphite matrix
Implementation Method 3
exemplary matrix materials include graphite
Data Source
AI summary
A method for making a phase change composite (PCC) for a battery pack of a plurality of electrochemical cells. The method includes impregnating a matrix material with a phase change material, and fragmenting the matrix material before or after the impregnating. The fragmented and impregnated matrix material are shaped into a composite such as by extraction, pressing, or other molding technique. Additional PCC shapes are provided by this invention, such as individual spacers for placement between individual battery cells, or rows of cells.