Battery Module Thermal Frame for Runaway-Resilient Cooling
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Solution Overview
Problem
Lithium-ion battery packs face challenges in dissipating heat effectively across a wide temperature range, particularly in extreme conditions, which can lead to thermal runaway and damage to adjacent cells.
Innovation Solution
The design incorporates a thermally conductive frame with apertures arranged in specific patterns, cooling ribbons extending from top to bottom, and a heating element on one side paired with a cooling plate on the other, along with potting material to isolate heat transfer between cells, enhancing thermal resilience and preventing thermal runaway.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If battery cells are arranged closely to increase energy density, then productivity and space utilization improve, but heat dissipation becomes insufficient and thermal runaway risk increases
Solution Approach 1:
The battery pack is divided into multiple modules, each with its own thermally conductive frame and cooling ribbons. This segmentation allows heat to be dissipated locally at the module level, preventing heat accumulation even when cells are closely arranged. The frame structure divides the battery pack into discrete thermal zones that can be managed independently.
Solution Approach 2:
A thermally conductive frame acts as an intermediary between battery cells and cooling plates. The frame includes cooling ribbons that extend from top to bottom, creating thermal pathways that facilitate heat transfer from cells to cooling plates without requiring direct cell-to-plate contact. This intermediary structure enables efficient heat dissipation while maintaining high cell density.
2Reliability
If thermal management components are added to improve heat dissipation, then thermal resilience improves, but device complexity increases
Solution Approach 1:
The thermally conductive frame serves multiple functions simultaneously: it provides structural support for battery cells, acts as a heat conduction pathway, and integrates cooling ribbons for thermal management. The heating elements and cooling plates are positioned on opposite faces of the same frame structure, allowing a single component to handle both heating and cooling operations, thereby reducing overall system complexity.
Solution Approach 2:
The patent combines the structural frame with thermal management functions by integrating cooling ribbons directly into the thermally conductive frame. The heating elements and cooling plates are merged into a unified thermal control system where the frame acts as both structural support and thermal conduit, reducing the number of separate components needed.
3Object-affected harmful factors
If potting material is used to isolate heat transfer between cells, then thermal runaway propagation is prevented, but heat dissipation from individual cells is reduced
Solution Approach 1:
Potting material is applied selectively in specific locations where thermal isolation is most critical, such as between adjacent cells and at interfaces where thermal runaway propagation risk is highest. This localized application maintains heat dissipation pathways while providing thermal isolation where needed, preventing the need to insulate entire cell surfaces.
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 allows for efficient heat dissipation and thermal management, maintaining battery module functionality even after a thermal runaway event, suitable for use in extreme conditions such as in a lunar rover.
Implementation Method 1
a thermally conductive frame configured to dissipate heat generated by the lithium-ion battery cells
Implementation Method 2
a heating element on one side paired with a cooling plate on the other
Implementation Method 3
a cooling plate on the other
Data Source
AI summary
A battery pack having a plurality of battery modules is provided. Each of the plurality of battery modules includes a thermally conductive frame having a plurality of apertures and a plurality of battery cells, wherein each of the plurality of battery cells is disposed in one of the plurality of apertures. Each of the plurality of battery modules also includes a heating element disposed on a top of the thermally conductive frame and a cooling plate disposed on a bottom of the thermally conductive frame. The thermally conductive frame includes a plurality of cooling ribbons disposed between at least two of the plurality of apertures, wherein each of the plurality of cooling ribbons extend from top of the thermally conductive frame to the bottom of the thermally conductive frame.