Thermally Insulated Current Collector Plates for Battery Modules
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional battery modules face the risk of thermal runaway propagation due to inadequate heat dissipation, where heat from a failed cell can cause adjacent cells to overheat, leading to potential battery fires and system failure.
Innovation Solution
A current collector system with thermally insulated current collector plates is introduced, where each battery cell is connected to a separate plate, distributing heat generated by a failed cell to a larger area and minimizing heat conduction between adjacent cells through the use of thermally insulating materials and perforated plates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional current collector plates are used to connect battery cells, then electrical conductivity and structural simplicity are improved, but heat dissipation capability deteriorates leading to thermal runaway propagation risk
Solution Approach 1:
The current collector system is divided into multiple independent current collector plates, each connected to specific battery cells. This segmentation isolates heat pathways so that thermal failure in one cell group does not propagate to adjacent groups through the current collector, directly addressing the thermal safety issue while maintaining electrical connectivity.
Solution Approach 2:
Thermally insulating materials are introduced as intermediaries between adjacent current collector plates. These materials block heat conduction paths while allowing electrical isolation, preventing thermal runaway propagation. The insulating materials act as mediators that maintain electrical functionality while blocking harmful thermal transfer.
2Quantity of substance
If battery cells are arranged in parallel configuration, then capacity is improved, but heat accumulation risk increases due to inadequate heat dissipation
Solution Approach 1:
Battery cells are grouped and connected to different current collector plates, segmenting the parallel configuration into smaller thermal zones. Each current collector plate manages heat for its connected cells independently, preventing heat accumulation across the entire parallel bank while maintaining total capacity.
Solution Approach 2:
The system transitions from a single-plane current collector arrangement to a multi-layer stacked structure with insulating materials between layers. This dimensional change creates three-dimensional heat dissipation pathways, allowing heat to be managed in multiple spatial directions rather than concentrating in a single plane.
3Speed
If current collector plates provide direct thermal conduction paths, then electrical connectivity is improved, but thermal runaway propagation speed increases
Solution Approach 1:
The current collector system is segmented into multiple isolated plates, each handling electrical connectivity for specific cell groups. This segmentation maintains high electrical conductivity within each plate while breaking continuous thermal conduction paths between adjacent plates, preventing rapid thermal runaway propagation.
Solution Approach 2:
Different regions of the current collector system have different thermal properties: current collector plates provide high electrical conductivity where needed, while insulating materials provide thermal isolation in between. This local differentiation of thermal quality allows electrical connectivity without compromising thermal safety.
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 effectively prevents thermal runaway propagation by distributing heat generated by a failed cell across a greater area, maintaining each battery cell's temperature below critical levels and reducing the risk of battery fires.
Implementation Method 1
a layer of thermally insulating material between the first current collector plate and the second current collector plate
Data Source
Figure 1~2B
Figure 3A~3B
Figure 4A~4C
AI summary
The present invention refers to a current collector system (5) for a battery module (4) comprising a plurality of battery cells (1) divided in at least a first group (1 a) and a second group (1b), wherein the current collector system (5) comprises a first current collector plate (3a) and a second current collector plate (3b) stacked on each other and thermally insulated from each other, wherein the first current collector plate (3a) is electrically connected to the battery cells of the first group (1 a) and the second current collector plate (3b) is electrically connected to the battery cells of the second group (1b). The present invention further refers to a battery module comprising a plurality of battery cells (1) divided in at least a first group (1a) and a second group (1b) and a current collector system (5), wherein the minimum distance (S) between two battery cells of the same group is greater than the distance between two adjacent battery cells in the battery module (10).