Dielectric-Coated Cold Plates With Venting for Battery Packs
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Solution Overview
Problem
Battery packs face challenges with heat generation, leading to condensate accumulation and increased chances of electrical shorting, and during faulty operations, outgases can cause pressure buildup and potential fire hazards, which existing cooling arrangements fail to adequately address.
Innovation Solution
The battery assembly incorporates cold plates with dielectric material coatings on sidewalls and edges to prevent electrical shorting and features openings for safe venting of outgases, along with a method of testing and reapplying coatings to ensure sufficient dielectric thickness, thereby preventing electrical shorting and reducing fire hazards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling arrangements are used to manage heat in battery packs, then temperature control is improved, but condensate accumulation occurs leading to increased electrical shorting risks
Solution Approach 1:
A dielectric material is introduced as an intermediary substance between the conductive cold plate and the surrounding environment. This dielectric coating prevents electrical shorting caused by condensate accumulation while allowing the cold plate to continue functioning as a heat sink. The dielectric material acts as a mediator that blocks electrical conductivity pathways without interfering with the thermal management function.
Solution Approach 2:
A thin dielectric coating is applied to the cold plate surface, forming a protective film that prevents electrical shorting. This thin film approach maintains the compact design while providing electrical isolation. The coating is sufficiently thin to not significantly impact thermal performance but thick enough to prevent condensate-induced shorting.
2Temperature
If cooling arrangements are used to manage heat in battery packs, then temperature control is improved, but outgases cause pressure buildup and fire hazards
Solution Approach 1:
Vent openings are incorporated into the cold plate structure to extract and vent outgases produced during battery faulty operations. By providing a dedicated escape path for gases through the cold plate, the system prevents pressure buildup and reduces fire hazards while maintaining the cold plate's primary cooling function.
3Reliability
If dielectric coating is applied to cold plates, then electrical shorting is prevented, but coating thickness uniformity becomes difficult to control
Solution Approach 1:
A preliminary coating layer is applied to the cold plate surface before the final dielectric coating. This preliminary layer serves as a base that improves the uniformity and adhesion of the subsequent dielectric coating, ensuring consistent electrical isolation properties across the entire surface while simplifying the manufacturing process.
Solution Approach 2:
A testing method is implemented to measure leakage current between the cold plate and adjacent conductive elements. This feedback mechanism allows verification of dielectric coating effectiveness, enabling quality control and reapplication of coating if necessary to ensure adequate electrical isolation.
4Object-affected harmful factors
If vent openings are added to cold plates, then outgases can be safely vented, but electrical shorting risk increases due to proximity of conductive elements
Solution Approach 1:
The dielectric coating serves as an intermediary barrier around the vent openings and on the cold plate surface, preventing direct electrical contact between conductive elements while allowing gas passage through the openings. This mediator enables both functions: electrical isolation and gas venting.
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
The solution effectively reduces electrical shorting and fire risks by ensuring adequate dielectric coating thickness and providing a safe path for outgases, enhancing the reliability and safety of battery assemblies, especially in high-altitude or high-conductivity environments.
Implementation Method 1
each of the one or more cold plates has a dielectric material coating on sidewalls and edges of the openings to prevent or reduce chances of electrical shorting
Implementation Method 2
A battery assembly includes a cooling arrangement including one or more cold plates
Implementation Method 3
cooling arrangement including one or more cold plates
Implementation Method 4
each cold plate has a plurality of openings to allow venting of outgases from corresponding one or more batteries
Data Source
AI summary
A method includes forming a cold plate including conductive material and having a plurality of openings, and coating the cold plate with dielectric coating. The method further includes placing the cold plate proximal to a metal plate including one or more metals, and exposing the cold plate to moisture and/or water. In an example, a minimum lateral distance between the cold plate and the metal plate is at most 0.5 inch. The method further includes, while the cold plate is exposed to the moisture and/or the water, applying a voltage across the cold plate and the metal plate, and measuring a resultant leakage current through the cold plate. A thickness of the dielectric coating on an edge of an opening of the plurality of openings is at least 0.003 inch.