Parallel-Cooled Battery Module Layout for Uniform Cell Temperature
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Solution Overview
Problem
Current energy-storage systems for vehicles face issues such as large size, inefficiency, poor safety, and inadequate thermal management, as well as vulnerability to crash forces and thermal runaway events.
Innovation Solution
The implementation of a vehicle energy-storage system with parallel cooling and flame-activated intumescent material sheets, featuring a modular design with cylindrical rechargeable battery cells, a current carrier, and a coolant system that maintains uniform temperature across all cells, along with protective enclosures and bus bars to prevent short circuits and redirect flames.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If current thermal management schemes are used for energy-storage systems, then cooling function is provided, but space consumption is excessive
Solution Approach 1:
The patent implements nested cooling channels within the battery module structure itself. The cooling channels are integrated into the module housing and positioned to directly contact or closely approach the battery cells, allowing the cooling system to be nested within the existing structural volume rather than adding separate external cooling equipment. This resolves the contradiction by providing effective thermal management while minimizing additional space consumption.
Solution Approach 2:
The patent transitions from conventional single-path cooling to a multi-dimensional parallel cooling architecture. Multiple cooling channels are arranged in parallel across different dimensions within the battery module, enabling simultaneous cooling of multiple cells through different spatial pathways. This dimensional expansion of the cooling approach improves temperature uniformity without proportionally increasing system volume.
2Productivity
If conventional energy-storage systems are used, then basic energy storage function is provided, but imbalance among battery cells and resistance in electrical connections cause inefficiency
Solution Approach 1:
The patent applies local quality optimization by providing individualized cooling channels for each battery cell or small groups of cells. This localized cooling approach allows each cell to be cooled according to its specific thermal conditions and operational state, preventing temperature-induced performance variations that lead to cell imbalance. The current carrier design also incorporates localized electrical connections optimized for each cell, reducing connection resistance variations across the battery pack.
Solution Approach 2:
The patent segments the battery system into modular units with independent cooling channels and electrical connections. Each module can be independently managed and optimized, allowing for better control of cell-to-cell variations. This segmentation enables targeted thermal management and electrical connection optimization, reducing overall energy loss from imbalance and resistance without requiring complex system-wide modifications.
3Reliability
If standard protective measures are used for energy-storage systems, then basic protection is provided, but protection from crash forces and thermal runaway is inadequate
Solution Approach 1:
The patent implements beforehand cushioning through multiple proactive protective measures: (1) Crash absorbers are pre-positioned between the battery modules and the vehicle frame to absorb impact forces before they reach the battery cells; (2) The modular enclosure structure is designed with inherent mechanical strength to protect cells from deformation during collisions; (3) Thermal isolation features are built into the module design to prevent thermal runaway propagation before it can affect adjacent cells. These pre-built protective features resolve the contradiction by providing comprehensive safety without requiring complex active protection systems.
Solution Approach 2:
The patent extracts and isolates critical protective functions into separate dedicated components: crash absorption is handled by dedicated crush zones and absorber structures separated from the battery cells; thermal protection is provided by independent thermal barriers and fire-resistant materials; electrical isolation is achieved through separate insulation layers. This extraction of protection functions into dedicated components simplifies the overall system architecture while maintaining high reliability, as each protection mechanism can be independently optimized without increasing overall device complexity.
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 results in a compact, efficient, and safer energy-storage system that maintains uniform battery cell temperatures, reduces the risk of thermal runaway, and protects against crash forces, enhancing the stability and performance of electric vehicles.
Implementation Method 1
a coolant system for circulating coolant flowing into the enclosure through the coolant input port and out of the enclosure through the coolant output port in parallel such that each of the battery cells is at approximately the same predetermined temperature
Implementation Method 2
a coolant system for circulating coolant flowing into the tray across the plurality of modules and battery cells in parallel such that each of the modules is at approximately the same predetermined temperature
Implementation Method 3
a plurality of intumescent material sheets that are flame-activated to redirect flames during a thermal event away from the battery modules and high voltage connections
Data Source
AI summary
Provided are systems for vehicle energy storage having parallel cooling comprising a plurality of modules. Each module may comprise two half modules coupled together. Each half module can include a plurality of battery cells. A current carrier of each half module may be electrically coupled to the cells. The cells may be disposed between the current carrier and a plate. Each half module can have the cells, current carrier, and blast plate disposed in an enclosure. The enclosure can have a coolant sub-system for circulating coolant in parallel to the plurality of cells such that each of the battery cells is at approximately the same predetermined temperature. The modules may be disposed in a tray. A coolant system may be provided for circulating coolant across the plurality of modules in parallel such that each of the modules can be maintained at approximately the same predetermined temperature.