Electrochemical Cell Casing with Phase Change Materials
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Solution Overview
Problem
Existing electrochemical device thermal management systems fail to effectively address the challenges of varying battery sizes, air gaps, impact resistance, ease of use, transport, waterproofing, corrosion resistance, and fire resistance, while also providing inadequate thermal management performance.
Innovation Solution
A casing or sleeve made of a polymer matrix with dispersed phase change materials (PCMs) and elastomeric materials, which is solid at room temperature, provides close contact with electrochemical cells, reducing operating temperatures and offering improved thermal management, impact resistance, and ease of application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If active cooling systems (forced air convection, fluidized cooling, heat pipes) are used to manage temperature fluctuations, then thermal management effectiveness is improved, but device complexity, weight, and cost increase
Solution Approach 1:
The patent employs phase change materials (PCMs) that undergo phase transitions (solid-liquid) at specific temperatures to absorb and release heat. The PCM is encapsulated in microcapsules and dispersed throughout the battery structure, enabling passive thermal regulation without complex active cooling systems. This resolves the contradiction by providing effective temperature management through material phase changes rather than mechanical cooling systems.
Solution Approach 2:
The patent creates a composite structure combining PCMs, conductive materials (graphene, carbon nanotubes), and battery components. This composite approach integrates thermal management functionality directly into the battery structure, eliminating the need for separate active cooling systems while maintaining temperature control effectiveness.
2Reliability
If existing insulators and protective covers are used to mitigate temperature escalation and protect cells, then some thermal management and mechanical protection is provided, but thermal management performance and comprehensive protection are inadequate
Solution Approach 1:
The PCM undergoes phase transitions at temperatures relevant to battery operation, absorbing heat during charging/discharging cycles and releasing it during cooling periods. This actively counteracts temperature escalation rather than merely insulating, providing superior thermal management performance and reliability.
Solution Approach 2:
The composite material integrates multiple functionalities: PCM for thermal regulation, conductive materials for heat distribution, and protective encapsulation for mechanical strength. This multi-functional composite provides both thermal management and mechanical protection, addressing the inadequacies of separate insulators and covers.
3Quantity of substance
If multiple battery or capacitor cells are packed near each other to achieve high power and energy density, then energy density is improved, but operating temperatures increase and safety risks worsen
Solution Approach 1:
The PCM distributed throughout the battery pack absorbs excess heat generated by densely packed cells during high-power operation. The phase transition process provides active cooling capacity that scales with the heat generation, enabling high cell density while maintaining safe operating temperatures.
Solution Approach 2:
The PCM acts as an intermediary thermal management medium between the battery cells and the external environment. It absorbs heat directly from the cells during operation and releases it during cooling phases, mediating the thermal interaction and enabling dense cell packing without temperature-related safety risks.
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 reduces operating temperatures by up to 10°C, enhances thermal management, and provides improved safety and longevity of electrochemical cells through better heat dissipation and resistance to physical stresses.
Implementation Method 1
At least one of the two or more temperature management materials may comprise a phase change material having a latent heat of at least 5 Joules per gram and a transition temperature between 0°C and 100°C
Implementation Method 2
at least one other of the two or more temperature management materials may comprise an elastomeric material
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 1E
AI summary
This disclosure provides casings and materials for the thermal management and protection of an electrochemical cell. The casing may comprise an inner surface configured to be in physical contact with at least a portion of an outer surface of an electrochemical cell. The inner surface may be substantially solid at room temperature. The casing may also comprise a polymer matrix which itself comprises two or more temperature management materials. At least one of the two or more temperature management materials may comprise a microencapsulated phase change material having a latent heat of at least 5 Joules per gram and a transition temperature between 0°C and 100°C, and at least one other of the two or more temperature management materials may comprise an elastomeric material. The polymer matrix may be substantially homogeneous.