EV Battery Cold Plate with Melting Inserts for Thermal Runaway
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Solution Overview
Problem
Existing temperature control systems for battery packs in electric vehicles are not readily replaceable or serviceable, and they fail to contain thermal runaway events effectively, leading to potential catastrophic breakdowns due to heat propagation between adjacent battery cells or packs.
Innovation Solution
A modular cold plate design with a top layer and a bottom layer, where the top layer has inserts that melt to expose openings and allow coolant release during thermal runaway, and the bottom layer has channels to circulate coolant away from the energy storage unit, preventing heat spread to adjacent cells or packs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional temperature control system is used for battery packs, then the system structure is simple, but the system is not readily replaceable or serviceable and fails to contain thermal runaway events effectively
Solution Approach 1:
The cold plate is divided into a top layer and a bottom layer that can be separated. The top layer contains openings that are sealed with inserts during normal operation, while the bottom layer contains coolant channels. This segmentation allows the components to be replaced or serviced independently, improving maintainability while maintaining thermal runaway containment through the modular structure.
Solution Approach 2:
The top layer is pre-configured with openings that are sealed by inserts before the battery pack is assembled or put into service. These inserts are designed to melt at specific temperatures, creating a preliminary containment structure that will automatically activate during thermal runaway events without requiring external intervention.
2Reliability
If the top layer has inserts that prevent coolant contact with battery surface, then normal temperature control is maintained, but coolant cannot rapidly respond during thermal runaway
Solution Approach 1:
The inserts are made of a material with a specific melting temperature that is lower than the battery operating temperature but sufficient to contain coolant during normal operation. During thermal runaway, when the temperature exceeds the insert melting point, the inserts automatically transition from solid to liquid state, opening the pathways for rapid coolant flow without requiring external control mechanisms.
Solution Approach 2:
The system uses the heat from the thermal runaway event itself to trigger the response mechanism. The excessive heat automatically melts the inserts, which in turn automatically opens the coolant pathways, allowing the system to self-regulate and respond to the emergency without external intervention or complex control systems.
3Productivity
If coolant channels are positioned close to battery cells for effective heat transfer, then temperature control efficiency is improved, but the risk of direct coolant contact during normal operation increases
Solution Approach 1:
The inserts act as an intermediary barrier between the coolant channels in the bottom layer and the battery cell surfaces. During normal operation, these inserts remain in place and prevent direct contact between the coolant and battery surfaces, eliminating the harmful effect while maintaining the beneficial close positioning for heat transfer efficiency.
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 modular cold plate design allows for controlled temperature regulation and containment of thermal runaway events, preventing heat propagation and ensuring the integrity of the energy storage system by allowing coolant to flow and dissipate heat effectively.
Implementation Method 1
The plurality of inserts can have a melting temperature lower than a melting temperature of the top layer. At least one of the plurality of inserts can melt to expose at least one of the plurality of openings responsive to the bottom surface of the energy storage unit heating the at least one of the plurality of inserts to the melting temperature of the plurality of inserts
Implementation Method 2
The channel can circulate coolant to transfer heat away from the energy storage unit
Data Source
AI summary
Apparatuses, systems, and methods of controlling of an energy storage unit are detailed herein. A cold plate can be thermally coupled with an energy storage unit for powering the electric vehicle. The cold plate can have a bottom layer. The bottom layer can have a channel spanning across a top surface of the bottom layer to circulate coolant to transfer heat away from the energy storage unit. The top layer can be flush with a bottom surface of the energy storage unit. The top layer can define openings each extending between the top surface and the bottom surface. The cold plate can have inserts sealing the openings. The inserts can have a melting temperature lower than a melting temperature of the top layer to expose at least one opening when heated the melting temperature to allow release of the coolant from the channel onto the energy storage unit.