Battery Cell Separation Element With Protruding Cooling Interface
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Solution Overview
Problem
Existing battery cooling systems face challenges in efficiently cooling battery cells without compromising safety, particularly in high-voltage battery modules used in motor vehicles, where thermal runaway can occur and risk thermal spread to neighboring cells.
Innovation Solution
The integration of passive cell separation elements that protrude from the gaps between battery cells, connected to an active cooling device, which are designed to provide enhanced thermal insulation and cooling without direct flow-through, using materials like metallic plates or phase change materials to manage thermal conductivity and prevent thermal events from spreading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cell separation elements are used to thermally insulate battery cells, then thermal insulation between cells is improved, but cooling efficiency deteriorates
Solution Approach 1:
The cell separation element acts as an intermediary component between battery cells, providing thermal insulation while incorporating a cooling channel that mediates heat removal. The element introduces a cooling medium through its thickness to actively remove heat from the battery cells, resolving the contradiction between insulation and cooling by adding a functional channel within the insulating structure.
Solution Approach 2:
The cell separation element performs multiple functions simultaneously: it provides thermal insulation between adjacent battery cells, electrically isolates the cells, and serves as a cooling component with integrated cooling channels. This multi-functionality allows a single component to address both thermal insulation requirements and active cooling needs, eliminating the trade-off between these opposing requirements.
2Temperature
If cooling channels are integrated into cell separation elements, then cooling efficiency is improved, but safety risk deteriorates due to potential leakage
Solution Approach 1:
The cell separation element serves as an intermediary barrier between the cooling medium and the battery cells. The cooling channels are integrated within the thickness of this insulating element, allowing heat to be conducted through the element while the element itself acts as a protective barrier that contains any potential leakage, preventing cooling medium from directly contacting the battery cells.
Solution Approach 2:
The cell separation element provides a protective barrier in advance against potential cooling medium leakage. By integrating the cooling channels within the thickness of this insulating element, the system prepares a safety mechanism that can contain and cushion any leakage before it reaches the battery cells, thus preventing safety issues before they occur.
3Volume of moving object
If cell separation elements are made thin for space saving, then space utilization is improved, but structural robustness deteriorates
Solution Approach 1:
The cell separation element exhibits local quality variations: it is thin in the region between battery cells to maximize space utilization, but extends with protruding portions beyond the cell gaps to provide robust connection surfaces for cooling devices. This localized thickness variation allows the element to be space-efficient where needed while maintaining structural strength where connections are required.
Solution Approach 2:
The cell separation element transitions from a two-dimensional thin barrier between cells to a three-dimensional structure with protruding portions that extend beyond the cell gaps. This dimensional transition allows the element to maintain thinness for space saving between cells while developing structural robustness through vertical extension for cooling device integration.
4Temperature
If protruding portions are added to cell separation elements for cooling device connection, then cooling capability is improved, but device complexity deteriorates
Solution Approach 1:
The cell separation element merges multiple functions into a single integrated structure: thermal insulation, electrical isolation, and cooling device connection. The protruding portions are not separate components but extensions of the cell separation element itself, combining the barrier function with the cooling interface function in one unified element, thereby reducing overall device complexity.
Solution Approach 2:
The cell separation element with protruding portions serves as a universal component that simultaneously provides thermal insulation between cells, electrical isolation, and mechanical connection for cooling devices. This multi-functionality eliminates the need for separate insulation elements and mounting structures, simplifying the overall system despite the enhanced cooling 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
This design achieves more efficient and homogeneous cooling of battery cells, preventing thermal runaway and enhancing safety by creating a robust thermal barrier while minimizing the risk of cooling medium leakage, thus providing effective cooling without additional installation space.
Implementation Method 1
At least one of the cell separation elements protrudes on one side of the cell stack from a gap between the two battery cells in which the cell separation element is arranged, wherein the protruding cell separation element is connected to an active cooling device through which a cooling medium can flow
Implementation Method 2
Cell separation elements can be provided between the battery cells of a battery module. These can take on various functions, such as insulating the battery cells electrically and thermally from one another
Data Source
AI summary
A battery arrangement with a battery module, which includes a cell stack with multiple battery cells arranged next to one another in a stacking direction and one or more cell separation elements. One of the cell separation elements is arranged between respective two battery cells arranged adjacent to one another. At least one of the cell separation elements protrudes on one side of the cell stack from a gap between the two battery cells, in which the cell separation element is arranged. The protruding cell separation element is connected to an active cooling device through which a cooling medium can flow and which is encompassed by the battery arrangement.