Stackable Cooling Element for Battery Thermal Management
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Solution Overview
Problem
Current accumulator technologies face challenges in efficiently managing temperature fluctuations and preventing thermal runaway, particularly in high-density cell stacks used in electric motor vehicles, where overheating can lead to rapid temperature increases and potential ignition of adjacent cells.
Innovation Solution
A cooling/heating element with a flow baffle system that regulates the flow of a cooling medium based on the distance between cell boundaries, preventing pressure imbalances and ensuring stable temperature control, while also incorporating a fire-resistant layer and channels for discharging hot gases to prevent thermal runaway.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the distance between cell boundaries increases to improve thermal management, then temperature control improves, but the packing density and energy content of the accumulator decreases
Solution Approach 1:
The cooling surface is divided into multiple cooling channels that are distributed between adjacent cells. This segmentation allows efficient heat removal from each cell while maintaining compact overall dimensions, resolving the contradiction between temperature control and packing density.
Solution Approach 2:
The cooling channels are arranged in a three-dimensional stackable configuration, allowing thermal management in the vertical dimension while maintaining horizontal packing density. The stackable design enables temperature control without sacrificing space efficiency.
2Device complexity
If simple cooling elements are used to reduce device complexity, then manufacturing and assembly become easier, but thermal runaway prevention capability is insufficient
Solution Approach 1:
The cooling element serves multiple functions simultaneously: it cools the cells through integrated cooling channels, provides thermal runaway prevention through fire screen layers, and enables stackable modular assembly. This multi-functionality maintains simplicity while achieving reliable thermal management and safety.
Solution Approach 2:
The cooling element combines different materials with complementary properties: thermally conductive materials for heat dissipation, fire-resistant materials for thermal runaway prevention, and sealed construction for fluid containment. This composite approach enhances reliability without significantly increasing complexity.
3Reliability
If active cooling is implemented to prevent thermal runaway, then safety improves, but energy consumption and system complexity increase
Solution Approach 1:
The cooling system utilizes the natural flow properties of the cooling medium and passive thermal conduction through the cooling elements. The design leverages inherent physical principles rather than requiring active energy-intensive cooling mechanisms, achieving thermal runaway prevention with minimal energy consumption.
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 maintains optimal cell temperatures, prevents thermal runaway, and ensures the safe operation of accumulator stacks by regulating pressure and heat dissipation, thereby protecting adjacent cells from overheating and ensuring the stability of the accumulator system.
Implementation Method 1
a flow screen (74) on the edge of the cooling surface (32, 58, 62, 72, 83), which throttles the inflow of a cooling/heating medium as the distance between the first and second boundary (13) increases
Implementation Method 2
a cooling surface with a first boundary (13), which is intended for physical contact with a first cell (11) of the accumulator, and a second boundary (13), which is provided for physical contact with a second cell (11) of the accumulator
Data Source
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AI summary
The invention relates to a cooling/heating element (12, 30, 30a, 30b, 40, 53, 60, 60a, 60b, 70, 70a, 70b, 81, 90, 181, 212, 214, 216) for an accumulator (170, 180, 210), comprising a cooling surface (32, 58, 62, 72, 83) with a first boundary (13), which is provided for physically contacting a first cell (11, 21, 51, 140, 150) of the accumulator (170, 180, 210), and a second boundary (13), which is provided for physically contacting a second cell (11, 21, 51, 140, 150) of the accumulator (170, 180, 210). According to the invention, the cooling/heating element (12, 30, 30a, 30b, 40, 53, 60, 60a, 60b, 70, 70a, 70b, 81, 90, 181, 212, 214, 216) is stackable and comprises an inlet (31, 54, 61, 71, 82) and/or an outlet (33, 55, 63, 73, 84) that interacts with an inlet (31, 54, 61, 71, 82) and/or outlet (33, 55, 63, 73, 84) of an adjacent cooling/heating element (12, 30, 30a, 30b, 40, 53, 60, 60a, 60b, 70, 70a, 70b, 81, 90, 181, 212, 214, 216) in a stack.