Modular Battery Modules With DX Cooling for Thermal Runaway Control
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Solution Overview
Problem
Centralized energy storage systems for lithium-ion batteries face challenges such as cell failure leading to thermal runaway, inefficient cooling systems, and high overhead weight and volume due to complex subsystems like intermediate DC buses and centralized cooling.
Innovation Solution
The implementation of universal battery modules connected via a universal bus, incorporating a power electronics transformer converter (PETC) system and a direct expansion (DX) based phase-change cooling system, which allows for modular, scalable, and efficient energy storage suitable for both stationary and portable applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If centralized cooling systems are used in energy storage systems, then cooling coverage is provided, but system complexity and overhead weight increase
Solution Approach 1:
The patent divides the cooling system into modular units, with each battery module having its own integrated cooling system rather than a single centralized cooling system. This segmentation reduces overall system complexity while maintaining adequate cooling coverage across all battery modules.
Solution Approach 2:
The cooling system is merged with the battery module structure itself, where cooling channels are integrated directly into the module housing. This combination eliminates the need for separate, complex external cooling systems and reduces overhead weight.
2Quantity of substance
If intermediate DC buses and centralized cooling subsystems are added, then energy storage capability is improved, but overhead weight and volume increase
Solution Approach 1:
Multiple functions including energy storage, cooling, and structural support are merged into the battery module itself. The module housing serves both as structural support and as the cooling system housing, eliminating redundant components and reducing overall system weight.
3Temperature
If centralized cooling systems are used, then thermal management is provided, but response time to thermal runaway increases
Solution Approach 1:
The cooling system is segmented into independent modular units at the battery module level. This allows localized thermal management responses, where a thermal runaway event in one module can be contained and addressed independently without waiting for a centralized system to respond, significantly reducing response time.
4Adaptability or versatility
If modular battery modules with integrated cooling are used, then portability is improved, but manufacturing complexity increases
Solution Approach 1:
The system is divided into standardized modular battery modules that can be manufactured independently using standardized processes. While each module has integrated cooling, the modular design allows for streamlined manufacturing and assembly, offsetting the increased complexity through standardization.
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 approach enhances thermal management, reduces the risk of thermal runaway, and increases energy density, leading to a more efficient, safer, and more portable energy storage system.
Implementation Method 1
a direct expansion (DX) based phase-change cooling system to remove heat from the modules
Data Source
AI summary
Described herein are systems for energy storage leveraging various advances in power electronics so that the systems are suitable for stationary and portable power applications. In some embodiments, a system includes a universal bus and universal battery modules connected to the universal bus, in which each module includes battery cells, a power electronics transformer converter (PETC) system, and a direct expansion (DX) based phase-change cooling system to reduce heat produced by the modules to provide a system that is suitable for stationary and portable power applications.