Variable Cross-Section Coolant Channels for Thermal Runaway Control
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Solution Overview
Problem
Battery modules face challenges in effectively managing thermal energy, as chemical reactions in rechargeable batteries can lead to thermal runaway events, causing heat to spread between adjacent cells and potentially affecting the entire module.
Innovation Solution
A heat-sink with variable cross-sectional area coolant channels that adjust in response to temperature changes, using restrictors and control plates to bias cooling towards affected cells and control the propagation of thermal runaway events.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If uniform coolant channel cross-sectional areas are used for all battery cells, then the cooling system structure is simple, but thermal runaway cannot be effectively controlled and heat spreads to adjacent cells
Solution Approach 1:
The patent implements variable cross-sectional area coolant channels where each channel's cross-section is tailored to the thermal characteristics of its associated battery cell. Cells with higher thermal risk or greater heat generation have larger coolant channel cross-sections, enabling localized optimization of cooling effectiveness without requiring a completely complex system redesign.
Solution Approach 2:
The patent incorporates expandable control plates that can dynamically adjust the coolant channel cross-sectional areas in response to temperature changes. When thermal runaway is detected, the control plates expand to increase the coolant channel cross-section, thereby dynamically adapting the cooling capacity to match the escalating thermal demand.
2Temperature
If coolant channel cross-sectional areas are increased to enhance cooling capacity, then thermal runaway control improves, but the heat-sink structure becomes more complex
Solution Approach 1:
The patent embeds expandable control plates within the coolant channels of the heat-sink structure. These control plates are nested inside the channels and can be activated to change the channel geometry, allowing the system to achieve variable cooling capacity without adding external or separate cooling mechanisms.
Solution Approach 2:
The patent changes the geometric parameter of the coolant channels by varying their cross-sectional areas. This is achieved through the expansion or contraction of control plates that modify the channel dimensions, thereby adjusting the cooling capacity to match the thermal requirements of different battery cells under different operating conditions.
3Reliability
If restrictors are used to limit coolant flow in normal conditions, then cooling is controlled, but thermal runaway response is delayed
Solution Approach 1:
The patent implements a feedback mechanism where temperature sensors monitor the thermal state of battery cells and signal the control plates to expand when thermal runaway conditions are detected. This closed-loop feedback system ensures that the coolant channel cross-sections are adjusted in direct response to actual thermal conditions, eliminating response delays.
Solution Approach 2:
The patent pre-configures the control plates within the coolant channels in a compressed state during normal operation. This preliminary configuration allows for rapid expansion when thermal runaway is detected, as the control plates are already in position and only need to expand rather than being deployed from scratch.
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 mitigates thermal runaway by selectively varying coolant channel cross-sectional areas, redirecting coolant flow to regions experiencing thermal issues, thereby preventing the spread of heat to adjacent cells without requiring external hardware or controls.
Implementation Method 1
each of the first and second control plates may be configured to expand when the temperature of the associated first or second battery cell is at or above the predetermined value and contract when the temperature of the associated first or second battery cell is below the predetermined value
Implementation Method 2
a heat-sink configured to absorb thermal energy from the first and second battery cells
Implementation Method 3
The coolant channel variable cross-sectional areas are configured to bias cooling to a region of the heat-sink proximate to the battery cell experiencing a thermal runaway event
Data Source
AI summary
A battery module includes a first battery cell and a neighboring second battery cell. The battery module also includes a heat-sink configured to absorb thermal energy from each of the battery cells. The heat-sink includes first and second coolant channels, each associated with and arranged proximate a corresponding first or second battery cell, configured to receive coolant, and defined by a respective cross-sectional area. Each coolant channel cross-sectional area is configured to selectively vary in response to a change in temperature of the associated first or second battery cell. The coolant channel variable cross-sectional areas are configured to bias cooling to a region of the heat-sink proximate to the battery cell experiencing a thermal runaway event and control propagation of the thermal runaway event to the other battery cell.