Flexible Cooling Unit for Pouch Cell Pressure and Heat Control
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Solution Overview
Problem
Pouch cell batteries used in land-based electric vehicles are unsuitable for aerospace applications due to high discharge rates, high altitude operation, vibration, mechanical stress, thermal runaway containment, and explosion containment challenges, which require effective cooling, pressure management, and structural support.
Innovation Solution
A thermal regulating unit with internal cooling channels and a flexible outer covering that presses against the battery for temperature regulation, mechanical support, and pressure management, integrated into a battery module with a non-combustible jacket and flame-retardant foam for containment, along with a coolant circuit for temperature control and pressure management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high discharge currents are drawn from the battery during takeoff and landing, then power output is improved, but internal cell heating increases and cell temperature rises
Solution Approach 1:
A thermal regulating unit with cooling channels is introduced as an intermediary between the battery cell and the external environment. The cooling channels convey coolant through the unit, which is in face-to-face contact with the battery, thereby transferring heat from the battery to the coolant without requiring direct modification to the battery structure itself.
Solution Approach 2:
The thermal regulating unit utilizes hydraulic cooling by conveying liquid coolant through internal cooling channels. This hydraulic system efficiently removes heat from the battery during high discharge operations, allowing sustained high power output without excessive temperature rise.
2Adaptability or versatility
If air pressure is reduced at high altitude, then operational capability is improved, but insulation properties of air decrease and thermal management becomes more difficult
Solution Approach 1:
The patent replaces reliance on air-based convection and conduction for thermal management with a liquid coolant-based hydraulic cooling system. This substitution ensures effective heat removal at high altitudes where air density and insulation properties are reduced, maintaining thermal regulation efficiency independent of atmospheric conditions.
3Reliability
If a restraining pressure is applied to the electrode stack to prevent expansion and contraction, then capacity degradation is reduced, but device complexity increases
Solution Approach 1:
The thermal regulating unit serves multiple functions simultaneously: it provides thermal regulation through cooling channels and applies restraining pressure to the electrode stack through its pressing mechanism. This multi-functionality reduces overall device complexity by combining thermal management and mechanical stabilization into a single integrated component.
Solution Approach 2:
The patent merges the thermal regulation function and the electrode stack restraining function into a single integrated unit. The thermal regulating unit both cools the battery and applies necessary pressure to prevent expansion-contraction cycling, thereby simplifying the overall system architecture.
4Reliability
If a support structure is added to dampen vibrations and support cells in any orientation, then mechanical reliability is improved, but device complexity increases
Solution Approach 1:
The thermal regulating unit simultaneously provides thermal regulation, restraining pressure, and vibration damping support. By integrating these functions into a single component, the patent avoids adding separate support structures that would increase device complexity while maintaining mechanical reliability under vibration and various orientations.
5Reliability
If a lightweight casing is designed for thermal runaway containment, then safety is improved, but structural strength may be compromised
Solution Approach 1:
The thermal regulating unit utilizes a flexible outer covering that can be made from thin, lightweight materials while still providing effective thermal runaway containment. The flexibility allows the material to deform and absorb energy during thermal events, maintaining containment capability without requiring heavy rigid structures.
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 cools the battery, manages pressure, provides mechanical support, and contains thermal runaway and explosions, ensuring safe and efficient operation of pouch cell batteries in aerospace environments.
Implementation Method 1
one or more internal cooling channels for conveying a liquid coolant through the unit
Implementation Method 2
inlet and outlet ports for conveying liquid coolant respectively to and from the one or more cooling channels
Implementation Method 3
the unit and the pouch cell battery can be held in face-to-face contact
Implementation Method 4
a flexible outer covering which contains the cooling channels
Data Source
AI summary
A thermal regulating unit for regulating the temperature of a pouch cell battery is provided. The thermal regulating unit is formed as a container having: one or more internal cooling channels for conveying a liquid coolant through the unit; a flexible outer covering which contains the cooling channels; and inlet and outlet ports which penetrate the covering for respectively providing liquid coolant to and removing the liquid coolant from the cooling channels. The flexible outer covering forms a substantially flat major external surface of the unit corresponding in shape to, and for pressing against, a major external surface of the pouch cell battery such that the unit and the pouch cell battery can be held in face-to-face contact. The cooling channels are arranged in the flexible outer covering such that when the provided liquid coolant is pressurized it causes the unit to expand and press against the major external surface of the pouch cell battery.