Multi-material cooling module for battery-cell tabs
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Solution Overview
Problem
Existing battery systems face challenges in effectively cooling battery-cell tabs, leading to potential thermal runaway and reduced longevity due to inadequate heat management.
Innovation Solution
A multi-material cooling module is introduced, comprising an isolation sheet and a heat exchanger with a metallic portion and a thermally conductive plastic portion, featuring a serpentine path for cooling fluid and baffles that provide structural support and enhance thermal conductivity, directly cooling battery-cell tabs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional cooling systems are used for battery cells, then cooling coverage is limited, but thermal management effectiveness deteriorates leading to thermal runaway risk
Solution Approach 1:
The cooling system is segmented into multiple independent cooling channels, each equipped with cooling plates that contact specific battery cell tabs. This segmentation allows targeted cooling of high-heat-generation areas (tabs) without requiring cooling of entire cell surfaces, improving thermal management effectiveness while reducing system complexity.
Solution Approach 2:
Cooling plates serve as intermediary components between the battery cell tabs and the cooling fluid channels. These plates conduct heat away from the tabs and transfer it to the cooling fluid, effectively mediating the heat transfer process and preventing direct thermal runaway while maintaining reliable thermal management.
2Temperature
If heavy metallic cooling structures are used, then thermal conductivity is improved, but weight increases reducing vehicle efficiency
Solution Approach 1:
The cooling module employs composite construction with cooling plates made of thermally conductive materials (metal or metal alloy) combined with structural supports made of lighter materials. This composite approach maintains high thermal conductivity for effective heat transfer while reducing overall module weight to improve vehicle efficiency.
Solution Approach 2:
High thermal conductivity materials are applied locally only where heat transfer is most critical (at the cooling plates contacting the tabs), while other structural portions use lighter materials. This localized application of thermal conductivity properties achieves effective cooling while minimizing overall weight of the cooling module.
3Ease of manufacture
If simple cooling channel designs are used, then manufacturing is easier, but cooling efficiency deteriorates due to inadequate heat dissipation paths
Solution Approach 1:
The cooling fluid pathway is segmented into multiple serial channels with cooling plates positioned at different locations along the flow path. This segmentation creates multiple heat dissipation stages, improving cooling efficiency as heat is progressively removed from different tab locations, while the modular segmented design remains relatively simple to manufacture.
Solution Approach 2:
The cooling system transitions from simple linear channels to a multi-dimensional arrangement with cooling plates extending into the battery pack depth direction and multiple channels arranged in series. This dimensional expansion provides adequate heat dissipation paths without significantly complicating manufacturing, as the additional channels can be formed using standard molding or machining processes.
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 solution effectively inhibits thermal runaway and extends the lifespan of battery packs by efficiently managing heat, ensuring reliable operation and safety.
Implementation Method 1
The lightweight portion is formed from a thermally conductive plastic material
Implementation Method 2
The plurality of baffles engages an interior surface of the metallic portion to thereby define a serpentine path for the cooling fluid
Data Source
AI summary
Systems, methods and a cooling module are described. The cooling module is configured to directly cool the plurality of battery cell tabs. The cooling module includes a generally prismatic isolation sheet contacting the battery cell tabs along a common plane and a heat exchanger. The heat exchanger includes a metallic portion defining an open cavity and a lightweight portion joined to the metallic portion to define a unitary flow assembly. The metallic portion includes an outer planar surface engaging the second planar surface. The lightweight portion is formed from a thermally conductive plastic material and includes baffles integrally formed with and extending therefrom. The plurality of baffles engage an interior surface of the metallic portion to thereby define a serpentine path for the cooling fluid.