Thermal Pyrolytic Graphite Cooling Plate for Battery Cell Heat Dissipation
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Solution Overview
Problem
High-power lithium-ion battery packs for PHEV applications face challenges in thermal management due to high cell temperatures and temperature differentials, particularly near terminal tabs, which can lead to reduced durability and increased cooling system complexity.
Innovation Solution
A thermal management system utilizing a cooling plate with thermal pyrolytic graphite (TPG) heat spreaders to enhance heat dissipation and uniformity, potentially eliminating the need for separate cooling of terminal tabs and busbars, and offering improved temperature control through indirect liquid cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high-capacity, high-power pouch cells are used in PHEV battery packs, then the battery pack capacity and power are improved, but the thermal load and cell temperatures increase significantly
Solution Approach 1:
The battery pack is divided into multiple modules (e.g., 8 modules in 96S1P configuration), each with its own cooling plate. This segmentation allows distributed thermal management, where each module's heat is handled independently, preventing thermal accumulation in any single region while maintaining high overall power capacity.
2Loss of energy
If direct cooling of terminal tabs and busbars is implemented, then ohmic heat dissipation is improved, but the cooling system complexity increases
Solution Approach 1:
The cooling function for both cell bodies and terminal tabs/busbars is merged into a single indirect liquid cooling system. The cooling plate simultaneously cools the cell through thermal conduction and dissipates ohmic heat from tabs/busbars via the liquid coolant circulating in channels, eliminating the need for separate cooling circuits and reducing system complexity.
Solution Approach 2:
An indirect liquid cooling system using a cooling plate as an intermediary medium is employed instead of direct contact cooling. The coolant circulates through channels in the cooling plate, transferring heat from both the cell and terminal regions without direct exposure, thereby simplifying the cooling architecture while effectively managing ohmic heat from busbars.
3Productivity
If high cell currents are used in EV mode operations, then the electrical energy consumption and EV range are improved, but the ohmic heat generation in tabs and busbars increases
Solution Approach 1:
The cooling plate design converts the harmful ohmic heat generated in tabs and busbars during high-current EV operations into a manageable thermal load. By incorporating liquid cooling channels that directly contact or are adjacent to the busbar regions, the system transforms excessive localized heat into controlled heat transfer to the coolant, which then dissipates it efficiently, allowing sustained high-current operation.
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 system effectively reduces maximum cell temperatures and temperature differentials, improving battery pack durability and simplifying cooling system design by enhancing heat spreading and dissipation capabilities.
Implementation Method 1
The cooling plate may include thermal pyrolytic graphite (TPG) to dissipate heat away from the at least one battery cell
Implementation Method 2
The temperatures of the cells in the battery pack may be managed with an indirect liquid cooling system
Data Source
AI summary
A thermal management system for a battery pack having at least one battery cell is provided. The thermal management system may include a cooling plate disposed adjacent to the at least one battery cell. The cooling plate may include thermal pyrolytic graphite (TPG) to dissipate heat away from the at least one battery cell.