Flexible Battery Packaging with Integrated Cooling Insert

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Solution Overview

Problem

Current cooling systems for battery packs are inefficient in maintaining temperature uniformity and are excessively heavy, particularly in automotive applications, leading to potential thermal runaway and reduced battery life.

Innovation Solution

Integration of a hollow, electrically insulating polymer insert within the flexible packaging of electrochemical accumulators to form a sealed coolant passage, eliminating the need for additional cooling pipes and reducing weight while maintaining effective thermal management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If conventional cooling systems with separate cooling pipes are used, then cooling function is provided, but weight increases and temperature uniformity decreases

Engineering Contradiction:

Improvetemperature uniformityVSAvoidcooling system weight

Core Design Contradiction:

TemperatureVSWeight of moving object

Solution Approach 1:

The patent merges the cooling function directly into the flexible packaging structure by integrating coolant passages within the packaging layers. This eliminates the need for separate cooling pipes and external cooling systems, thereby reducing overall weight while improving temperature uniformity across the battery pack through direct contact cooling.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The flexible packaging serves multiple functions simultaneously: it provides mechanical containment for the electrochemical cells, electrical insulation, and thermal management through integrated coolant passages. This multi-functionality eliminates the need for separate dedicated cooling components, reducing weight while maintaining effective cooling.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If flexible packaging is used, then weight is reduced and adaptability is improved, but sealing capability and structural strength decrease

Engineering Contradiction:

Improvepackaging flexibilityVSAvoidpackaging sealing capability

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The flexible packaging is constructed as a composite structure with multiple layers including polymer films and aluminum foil. This composite design maintains flexibility and adaptability while providing enhanced sealing capability and structural strength through the combination of different material properties.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The coolant passages are integrated within the layered structure of the flexible packaging, with each layer contributing to the overall functionality. The packaging structure contains nested functional elements (electrochemical cells, current collectors, and coolant passages) that work together while maintaining the flexible form factor.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Strength

If rigid packaging is used, then sealing and strength are improved, but weight increases and cooling efficiency decreases

Engineering Contradiction:

Improvepackaging sealing capabilityVSAvoidpackaging weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent employs flexible packaging with integrated coolant passages instead of rigid containers. The flexible nature of the packaging allows for better thermal contact with the electrochemical cells, improving cooling efficiency, while the integrated design eliminates heavy rigid cooling components.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The packaging structure combines mechanical containment and thermal management functions into a single integrated component. The coolant passages are formed within the flexible packaging itself, eliminating the need for separate rigid cooling systems and reducing overall weight.

Inventive Principle:

Principle #5Merging (Combining)

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 solution enhances temperature uniformity and reduces weight in battery packs, improving thermal management and extending battery life by integrating a sealed coolant passage within the flexible packaging, suitable for high-power applications.

Implementation Method 1

The hollow tube internally delimiting a conduit for passage of a cooling fluid... All areas of the accumulators directly adjacent to the hollow inserts can be cooled by conduction with the cooling fluid circulating in the inserts

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentEP3840099A1Electrochemical accumulator, in particular a metal-ion accumulator, with flexible packaging including one or more holes for cooling fluid to pass, associated module and manufacturing method

Publication Date: 2021.06.23 COMMISSARIAT A LENERGIE ATOMIQUE ET AUX ENERGIES ALTERNATIVES

Figure 1~2
Figure 3~4
Figure 5~6

AI summary

The invention relates to an electrochemical accumulator (A), in particular a metal-ion accumulator, comprising at least one electrochemical cell and a flexible package (6) arranged to contain the at least one electrochemical cell with a seal while being traversed by a part of the current collectors forming the output terminals (4, 5) of the accumulator, the flexible package integrating in a zone beyond the electrochemical cell(s) at least a part of at least one rigid insert (10) made of electrically insulating material at least for its portion(s) inside the flexible package, the insert being in the form of a hollow tube internally delimiting an orifice (8) for the passage of cooling fluid.