PCM Battery Module Layout for Uniform Cell Temperature Control
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Solution Overview
Problem
Current battery thermal management systems using phase-change materials (PCMs) face issues such as low thermal conductivity, risk of liquid leakage, volume change during phase transition, increased weight, and cost, failing to account for individual cell behavior and leading to thermal runaway.
Innovation Solution
A battery thermal management system utilizing stratified heat storage units with encapsulated solid-liquid or solid-solid PCMs, coupled with a microfluidic thermal control circuit, ensures temperature uniformity by independent heat transfer circuits and smart regeneration, addressing thermal gradients and potential runaway.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If plate exchanger with heat transfer fluid is used for thermal management, then cooling capability is provided, but individual cell thermal behavior is not accounted for and temperature uniformity is poor
Solution Approach 1:
The battery is divided into multiple thermal management zones corresponding to different cell groups. Each zone has its own PCM module that independently manages thermal behavior, allowing individual cell thermal characteristics to be accounted for while maintaining system simplicity through modular design.
Solution Approach 2:
Different PCM modules are strategically positioned to contact specific cells or cell groups based on their individual thermal behavior patterns. This local customization of thermal management allows each cell to receive appropriate cooling/heating tailored to its specific thermal characteristics, improving overall temperature uniformity.
2Temperature
If active thermal management system is used, then temperature control is provided, but energy consumption increases and system complexity increases
Solution Approach 1:
The system uses periodic charging/discharging cycles of the PCM to manage battery temperature. During high-temperature periods, the PCM absorbs heat; during low-temperature periods, it releases heat. This periodic thermal regulation provides precise temperature control without continuous energy input, reducing overall energy consumption compared to always-active cooling systems.
Solution Approach 2:
The PCM modules autonomously regulate battery temperature based on thermal conditions without requiring external control systems or continuous energy input. The phase-change material naturally absorbs and releases heat according to battery thermal needs, providing self-regulating temperature control that eliminates the energy consumption associated with active pumps, fans, or controlled circulation systems.
3Use of energy by moving object
If passive thermal management system is used, then energy consumption is reduced, but temperature control precision is insufficient
Solution Approach 1:
The system exploits the phase-change parameter of the PCM materials, which undergo specific phase transitions at defined temperature points. This parameter change enables the passive system to achieve precise temperature control, as the phase transition occurs at a specific temperature threshold, automatically regulating battery temperature without energy input while maintaining high precision control.
4Loss of time
If fast charging is implemented, then charging time is reduced, but thermal effects increase and cell degradation accelerates
Solution Approach 1:
The PCM modules are pre-positioned around the battery cells and maintain readiness to absorb thermal energy. During fast charging operations, the PCM immediately begins absorbing the intense heat generated by high charging currents, preventing temperature spikes before they can cause cell degradation. This preliminary thermal buffering capability enables sustained fast charging without compromising cell temperature or accelerating degradation.
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 system effectively maintains cell temperatures below a threshold, preventing thermal runaway by precise temperature control and reducing the need for active cooling systems, enhancing battery autonomy and safety.
Implementation Method 1
comprises a phase-change material (PCM) and a heat-conductive material
Implementation Method 2
Phase Change Materials Application in Battery Thermal Management System: A Review, Materials 2020, 13, 4622
Implementation Method 3
said composites being thermally conductive
Data Source
AI summary
A battery comprising one or more electrochemical cells and solid-liquid phase-change material composites, the battery comprising a plurality of modules, each having a given composite, the modules having an individual configuration, in which each module has an opening used to surround part of a cell inserted into the opening, a cell being surrounded along its height by a plurality of individual modules stacked on top of one another, with at least two modules having different composites, this individual configuration being implemented for one or more cells, and/or having a collective configuration, in which each collective module has a plurality of openings used to surround part of a plurality of cells inserted into the openings, the cells being surrounded along their height by a plurality of horizontal collective modules stacked on top of one another, with at least two modules having different composites.