Pouch Cell Tab Cooling to Reduce Jelly Roll Thermal Gradients
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing thermal management systems for battery packs, particularly in vehicle applications, face challenges in maintaining battery cells within a desirable temperature range, controlling maximum and minimum cell temperatures, reducing thermal gradients across internal jelly roll layers, and achieving efficient cooling without increasing weight or causing inhomogeneous heat distribution.
Innovation Solution
A pouch cell tab cooling system where tabs are submerged in a cooling material, such as a liquid or vapor, within an enclosure to directly cool the jelly roll, reducing thermal gradients and system weight while improving thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional surface cooling methods are used for battery packs, then cooling coverage is provided, but thermal gradients across internal jelly roll layers remain high and cooling efficiency is reduced
Solution Approach 1:
The patent uses tabs as intermediary heat transfer elements that directly contact the cooling material. Instead of cooling the entire battery surface, the cooling material is applied specifically to the tabs which then conduct heat away from the internal jelly roll layers, effectively reducing thermal gradients while improving cooling efficiency.
Solution Approach 2:
The patent employs liquid cooling material (such as dielectric fluid) that is circulated or applied to the tabs. This hydraulic approach allows for efficient heat removal through the tabs, directly addressing the thermal management needs of the battery cells without requiring complex surface cooling systems.
2Temperature
If comprehensive cooling systems are implemented to manage all battery surfaces, then temperature control is provided, but system weight increases
Solution Approach 1:
The patent applies cooling material locally to the tabs rather than covering the entire battery surface. This localized approach provides effective temperature control at the critical heat generation points (tabs connected to jelly roll) while significantly reducing the amount of cooling material and system weight required compared to comprehensive surface cooling.
Solution Approach 2:
The patent extracts the essential cooling function from the tabs, which are natural heat pathways from the jelly roll. By focusing cooling efforts on these extracted key elements rather than the entire battery surface, effective temperature control is achieved with minimal system weight.
3Temperature
If cooling material is applied to tabs, then thermal gradients are reduced and cooling efficiency improves, but manufacturing complexity increases
Solution Approach 1:
The tabs serve multiple functions: they are both electrical conductors for current flow and heat transfer pathways for thermal management. This multi-functionality means the existing tab structure can be utilized for cooling purposes without adding separate cooling components, thereby reducing manufacturing complexity while achieving thermal gradient reduction.
Solution Approach 2:
The tabs naturally serve as heat conduction pathways from the jelly roll to the external environment. By applying cooling material to these self-service heat pathways, the system utilizes its own structural elements for thermal management, avoiding the need for additional manufacturing steps or complex cooling system integration.
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 approach achieves better thermal management with reduced thermal gradients and longer cycle life for pouch cells, while minimizing weight and enhancing cooling efficiency by focusing on tab cooling rather than traditional surface cooling methods.
Implementation Method 1
the at least one of the first tab and the second tab submerged within the first cooling material, and wherein the first cooling material is configured to cool the at least one of the first tab and the second tab
Data Source
AI summary
Systems and methods for a battery pack are disclosed. A battery pack tab cooling system is disclosed that includes a pouch cell comprising a first tab and a second tab. The battery pack tab cooling system also includes an enclosure configured to contain a cooling material. The first tab and the second tab extend from the pouch cell into the enclosure and are in contact with the cooling material. A method of manufacturing a battery pack that includes forming the battery pack, the battery pack comprising and cooling the at least one of the first tab and the second tab to cool the pouch cell.