Phase Change Cooling Element for Battery Thermal Runaway Prevention

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Solution Overview

Problem

Conventional cooling methods for electrochemical cells are inefficient, costly, and can promote thermal energy propagation, posing safety risks in vehicle energy systems due to inability to effectively absorb excessive heat and separate overheated cells.

Innovation Solution

A cooling element made of a metal alloy that melts at a eutectic temperature, creating an air gap to prevent thermal propagation and incorporating spacers for structural integrity and thermal separation, which can be used in energy storage systems to absorb heat and detect faults.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If conventional cooling channels with fluid exchange are used to cool electrochemical cells, then cooling function is provided, but thermal energy propagation is promoted and cost increases

Engineering Contradiction:

Improvecell temperatureVSAvoidthermal energy propagation

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The patent extracts the cooling function from a complex fluid-based cooling channel system and implements it through a simple phase-change material (PCM) that absorbs heat directly through phase transition. The PCM is placed in direct thermal contact with the cell, eliminating the need for fluid circulation systems while preventing thermal propagation through the phase change mechanism.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent changes the thermal management approach from active fluid-based cooling to passive phase-change cooling. By utilizing the phase transition temperature (melting point) of the PCM, the system absorbs excessive heat at a specific temperature threshold, preventing thermal propagation without requiring complex cooling infrastructure.

Inventive Principle:

Principle #35Parameter changes

2Temperature

If conventional cooling elements are used to absorb heat, then cooling is provided, but volumetric and thermal efficiency is poor

Engineering Contradiction:

Improveheat absorption capacityVSAvoidcooling element volume

Core Design Contradiction:

TemperatureVSVolume of stationary object

Solution Approach 1:

The patent utilizes phase transition of a PCM that occurs at a specific temperature range. The PCM absorbs large amounts of heat during the phase change from solid to liquid, providing high thermal efficiency in a compact volume. This phase change mechanism allows the cooling element to absorb excessive heat without requiring large thermal mass or volume.

Inventive Principle:

Principle #36Phase transitions

3Temperature

If cooling elements fail to absorb excessive heat, then cooling function is lost, but heat returns to the electrochemical cell causing overheating

Engineering Contradiction:

Improveheat absorptionVSAvoidcooling reliability

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The PCM cooling system is self-regulating and requires no external control or power supply. When the cell temperature exceeds the PCM's melting point, the PCM automatically absorbs heat through phase change. When the temperature drops below the melting point, the PCM solidifies and releases less heat, automatically maintaining thermal balance without external intervention.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The phase transition mechanism provides a reliable thermal buffer that activates automatically at specific temperature thresholds. The PCM absorbs heat during melting when the cell overheats and solidifies when cooling is sufficient, providing fail-safe thermal management that prevents heat return to the cell.

Inventive Principle:

Principle #36Phase transitions

4Temperature

If conventional cooling methods are used, then cooling is provided, but cost increases and safety is compromised

Engineering Contradiction:

Improvethermal managementVSAvoidmanufacturing cost

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The patent employs a simple PCM material that can be a cost-effective alternative to complex cooling systems. The PCM is placed in direct contact with the cell and can be replaced or regenerated if needed, providing an economical solution that sacrifices complexity for reliability and cost-effectiveness in thermal management.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 provides efficient, cost-effective thermal management, preventing overheating propagation and enhancing safety in vehicle energy systems by effectively absorbing heat and detecting faults, thus maintaining system integrity and passenger safety.

Implementation Method 1

a cooling element configured to engage the electrochemical cell and absorb thermal energy from the electrochemical cell

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Implementation Method 2

The metal element is configured to melt into a liquid when the electrochemical cell exceeds an eutectic temperature of the metal element

Methodology Applied

Scientific EffectPhase change (melting): Melting

Data Source

PatentUS9090176B2Method and device for electrochemical cell propagation avoidance in a battery module

Publication Date: 2015.07.28 FCA US LLC

AI summary

A method and device for cooling an electrochemical cell is provided. In one embodiment, the cooling element for an electrochemical cell includes a metal element configured to engage with an electrochemical cell and absorb thermal energy from the electrochemical cell. The metal element is configured to melt into a liquid when the electrochemical cell exceeds an eutectic temperature of the metal element.