Multilayer PCM Composite Cooling for Battery Thermal Runaway
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Solution Overview
Problem
Existing thermal management systems for heat-producing devices, such as electronic components and batteries, face challenges in providing sufficient cooling capacity without increasing the device's footprint, leading to performance limitations and potential thermal runaway issues, especially during peak power consumption or thermal runaway events.
Innovation Solution
A thermal management system utilizing a multilayer phase change material composite structure with a supporting structure and pores filled with phase change materials, including water for enhanced heat absorption and fire-retardant properties, to control and dissipate heat efficiently, incorporating elements like heat sinks and fluid channels for active and passive cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If existing cooling technologies (heat spreaders, fans, heat sinks, fins, heat pipes) are used to increase cooling capacity, then cooling performance is improved, but device footprint increases
Solution Approach 1:
The patent utilizes phase change materials (PCMs) that undergo phase transitions (solid-liquid-gas) to absorb and dissipate heat. The PCM absorbs heat during phase change from solid to liquid, and further heat during evaporation from liquid to gas, providing high cooling capacity in a compact form factor without requiring additional cooling components
Solution Approach 2:
The patent employs composite material structures combining porous substrates with phase change materials. The composite structure integrates the heat absorption capability of PCMs with the thermal conductivity and structural support of porous materials, achieving efficient heat management in limited space
2Reliability
If cooling capacity is increased to prevent thermal runaway, then safety is improved, but device complexity increases
Solution Approach 1:
The phase change material system operates autonomously without requiring external control mechanisms. The PCM automatically absorbs heat during phase transitions when temperature rises, providing self-regulating thermal protection against thermal runaway without increasing system complexity or requiring additional sensors and control circuits
Solution Approach 2:
The patent leverages the inherent phase transition properties of materials to create a passive safety mechanism. The phase change process naturally occurs at specific temperature thresholds, providing automatic thermal protection without complex active cooling systems
3Temperature
If phase change materials are used for cooling, then cooling efficiency is improved, but thermal conductivity may be insufficient
Solution Approach 1:
The patent creates composite structures where phase change materials are integrated with thermally conductive porous substrates. This combination maintains the high cooling efficiency of PCMs while the conductive substrate ensures adequate heat transfer to the PCM, resolving the thermal conductivity limitation
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 manages heat without increasing device size, maintaining safe operating temperatures and preventing thermal runaway, while ensuring high thermal conductivity and mechanical resilience, thus enhancing device performance and safety.
Implementation Method 1
a phase change material positioned within the pores of the structure
Implementation Method 2
phase change materials, such as water... to control and dissipate heat efficiently
Implementation Method 3
heat sinks and fluid channels for active and passive cooling
Implementation Method 4
fluid channels for active and passive cooling
Data Source
AI summary
The invention relates to thermal management systems for devices that generate heat, including electronic devices such as portable electronics, for example, cell phones, electronic components, and/or battery systems. A multilayer phase change material composite structure may include multiple layers having different properties. For example, a PCM material composite layer may include a supporting structure having pores and a phase change material. Further, a layer of fire retardant material may be used in the multilayer phase change material. In some embodiments, additional layers such as coatings, thermal interface materials, and/or high thermal conductivity material may be present. A matrix formed from a porous supporting structure and a phase change material may be used to control and/or dissipate heat in a thermal management system. Support elements may provide stability. The thermal management system may mitigate conditions that could lead to a thermal runaway event and/or may influence conditions within the system during a potential thermal runaway event to reduce risk of fire. The thermal management system may include water, flame- and/or fire-retardant materials to control temperatures of an energy storage device and/or system. A housing may be used to surround a portion of a heat generating device such as an energy storage device or system, for example, an individual battery or a group of batteries, respectively. The housing or enclosure may include interior structures that surround and in some cases electrically isolate batteries from a thermal sink that includes a porous flame- and/or fire-retardant material having water in the pores.