Polymer Cooling Channels for Li-Ion Battery Thermal Runaway
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Solution Overview
Problem
Large scale energy storage systems, particularly Li-ion batteries, face challenges with thermal runaway, where excessive heat can spread quickly between cells, leading to flammable gas release and self-ignition, and existing cooling methods are inefficient, adding weight and volume while compromising safety and performance.
Innovation Solution
The use of polymer-based cooling fluid channels with a melting point between 100° C. and 400° C. that melt to provide direct cooling in case of thermal runaway, allowing for effective heat transfer and containment of heat within individual cells, reducing the risk of heat transfer to neighboring cells and flammable gas ignition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional cooling methods are used for energy storage devices, then cooling effectiveness is achieved, but weight and volume increase
Solution Approach 1:
The cooling channel material's melting point parameter is changed to be between 100°C and 400°C, allowing the channel structure itself to respond to thermal conditions. This enables the cooling system to adapt its configuration based on temperature, providing effective cooling during normal operation while minimizing structural weight and volume.
Solution Approach 2:
The cooling channel is made from polymer material that combines structural functionality with thermal-responsive properties. This composite approach allows the single component to serve both as a structural element and a thermal management device, reducing the need for additional heavy cooling components.
2Temperature
If conventional cooling methods are used for energy storage devices, then cooling effectiveness is achieved, but device complexity increases
Solution Approach 1:
The cooling channel is merged with the mounting structure to form an integrated cooler assembly. The energy storage device is mounted directly on the cooler, combining the mounting function and cooling function into a single integrated structure, thereby reducing device complexity while maintaining cooling effectiveness.
Solution Approach 2:
The cooling channel structure serves multiple functions: it provides structural support for mounting the energy storage device, acts as a cooling fluid conduit, and serves as a thermal management component. This multi-functionality reduces the number of separate components needed, simplifying the overall device complexity.
3Reliability
If cooling channels are made from polymer material with melting point between 100°C and 400°C, then thermal runaway containment is improved, but cooling channel integrity may be compromised at high temperatures
Solution Approach 1:
The potential weakness of polymer material at high temperatures is converted into a safety feature. When thermal runaway occurs and temperature exceeds the polymer's melting point, the cooling channel melts to allow direct contact between cooling fluid and the energy storage device, providing emergency cooling. The harmful effect of material degradation at high temperature is transformed into a beneficial automatic safety response.
Solution Approach 2:
The melting point parameter of the cooling channel material is specifically selected between 100°C and 400°C to create a threshold response. Below this temperature range, the channel maintains structural integrity for normal cooling; above this range, the material undergoes phase change to enable emergency cooling, thus improving thermal runaway containment while maintaining normal operational reliability.
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 effectively prevents thermal runaway from spreading, increases the operational lifetime of energy storage modules by maintaining uniform cell temperatures, and reduces weight and volume through direct cooling, enhancing safety and efficiency in marine and offshore applications.
Implementation Method 1
the channels being in contact with a surface of the energy storage device, each cooling fluid channel being adapted to receive cooling fluid from a source of cooling fluid, extract heat from the energy storage device
Implementation Method 2
wherein the cooling fluid channels comprise a polymer material, in particular polythene, polyamide, or thermal plastic; and wherein at least a part of the cooling fluid channel comprises a material having a melting point between 100° C. and 400° C.
Data Source
AI summary
An energy storage module with one or more energy storage devices and a cooler on which the energy storage device is mounted in contact with the energy storage device. The cooler has one or more cooling fluid channels for circulating cooling fluid, the channels being in contact with a surface of the energy storage device, each cooling fluid channel being adapted to receive cooling fluid from a source of cooling fluid, extract heat from the energy storage device and return the cooling fluid to the source. At least a part of the cooling fluid channel includes a material having a melting point above 100° C.