Lightweight Thermal Adsorption Structure for Lithium-Ion Modules

The thermal management structure is segmented into multiple layers with different functions: a first layer containing phase change material pockets for thermal regulation, and a second layer with thermal conductive material for heat dissipation. This segmentation allows each layer to optimize its specific function while reducing overall material usage compared to a monolithic phase change material structure.

Phase change material is strategically placed only in specific locations where thermal management is most critical (in pockets within the first layer), rather than uniformly distributing it throughout the entire structure. This local quality approach provides effective thermal management where needed while minimizing unnecessary weight from excessive material usage.

The structure converts the harmful heat generated during fast charging into a beneficial thermal management opportunity by using phase change material to absorb the heat at controlled rates. The phase change material undergoes phase transition (absorbing latent heat) which converts the harmful thermal energy into a controlled phase change process, preventing dangerous temperature rises while enabling continued fast charging.

Phase change material is utilized to manage heat through phase transition (e.g., solid to liquid or liquid to gas). During fast charging, the phase change material absorbs excess heat by undergoing phase transition, effectively converting thermal energy into latent heat of transformation. This allows the system to tolerate higher charging rates by managing the resulting heat through controlled phase changes rather than direct temperature increases.

The thermal management structure uses layers with uniform material properties and consistent pocket distributions to achieve homogeneous thermal contact with the battery cells. The phase change material is uniformly distributed within pockets across the first layer, and the thermal conductive material in the second layer provides consistent thermal pathways, ensuring uniform temperature distribution without requiring complex asymmetric structures.

The thermal management structure serves multiple functions simultaneously: the first layer with phase change material pockets provides both thermal absorption and structural support, while the second layer provides thermal conduction and cell spacing. This multi-functionality reduces the need for separate dedicated components, achieving uniform thermal contact without proportionally increasing structural complexity.