Pouch Cell Cooling Structure With Pressurized Contact Support
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Solution Overview
Problem
Aerospace battery modules face challenges such as high discharge rates causing internal heating, high altitude operation reducing insulation effectiveness, vibration and mechanical stress, thermal runaway containment, and explosion containment, which existing designs fail to adequately address.
Innovation Solution
A battery module comprising pouch cell batteries with thermal regulating units featuring internal cooling channels and flexible outer coverings that exert pressure and provide mechanical support, along with a casing filled with flame-retardant expanded foam to manage temperature, vibrations, and potential explosions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high discharge rates are used to meet power demands during takeoff and landing, then power delivery is improved, but internal cell heating and temperature gradients increase, reducing cell cycle life
Solution Approach 1:
The battery module is divided into multiple individual pouch cells, each with its own thermal regulating unit. This segmentation allows independent thermal management of each cell, enabling effective cooling even at high discharge rates by directing coolant flow to specific hot spots.
Solution Approach 2:
A liquid coolant is introduced as an intermediary thermal management medium. The coolant circulates through cooling channels in contact with each pouch cell, absorbing heat generated during high discharge operations and transferring it away from the cells, thus maintaining acceptable operating temperatures.
2Duration of action of stationary object
If adequate cooling is provided to maintain uniform temperature, then cell cycle life is improved, but device complexity increases due to additional thermal management components
Solution Approach 1:
The thermal regulating unit merges multiple functions into a single integrated component: the flexible outer covering provides both structural containment and thermal conduction pathways, while the spacer element simultaneously maintains cell spacing and facilitates coolant distribution. This merging reduces overall system complexity compared to separate cooling apparatus.
Solution Approach 2:
The flexible outer covering serves multiple functions: it contains the spacer element and coolant channels, provides thermal conduction contact with the pouch cell, maintains mechanical pressure on the cell, and allows for expansion/contraction accommodation. This multi-functionality eliminates the need for separate components for each function.
3Weight of moving object
If lightweight casing is used to reduce weight, then weight penalty is reduced, but explosion containment capability deteriorates under vacuum conditions
Solution Approach 1:
The module employs composite construction with the flexible outer covering made from materials that provide both lightweight properties and adequate mechanical strength. The covering is designed to contain explosion forces while maintaining acceptable weight, potentially using layered or reinforced polymer structures that balance these competing requirements.
Solution Approach 2:
The flexible outer covering is designed with inherent compliance and energy-absorbing characteristics that provide beforehand cushioning against explosion forces. The material can deform and absorb energy from potential thermal runaway events, preventing catastrophic failure while maintaining lightweight construction.
4Reliability
If restraining pressure is applied to electrode stack to prevent expansion and contraction cycling, then capacity degradation is reduced, but device complexity increases
Solution Approach 1:
The flexible outer covering provides self-service pressure regulation through its elastic properties. As the pouch cell expands or contracts during charge/discharge cycles, the covering automatically adjusts its constraining force, providing consistent restraining pressure without requiring external actuators or complex mechanical 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 batteries during high discharge, maintains uniform temperature, supports mechanical stability, contains thermal runaway, and prevents explosion-related smoke and debris release, ensuring safe and efficient operation 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 which penetrate the covering for respectively providing liquid coolant to and removing the liquid coolant from the one or more cooling channels
Implementation Method 3
The one or more 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 exert pressure against the major external surface of the pouch cell battery
Implementation Method 4
Spaces within the casing surrounding the pouch cell batteries and thermal regulating units are filled with flame-retardant and electrically-insulating expanded foam
Implementation Method 5
Spaces within the casing surrounding the pouch cell batteries and thermal regulating units are filled with flame-retardant and electrically-insulating expanded foam
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A thermal regulating unit (40) for regulating the temperature of a pouch cell battery (30) is provided. The thermal regulating unit is formed as a container having: one or more internal cooling channels (50) for conveying a liquid coolant through the unit; a flexible outer covering (42) which contains the cooling channels; and inlet and outlet ports (46) 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.