Method for mitigating thermal propagation of batteries using heat pipes
09689624 ยท 2017-06-27
Assignee
Inventors
Cpc classification
Y02T90/16
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
H01M10/6552
ELECTRICITY
B60L58/18
PERFORMING OPERATIONS; TRANSPORTING
F28F2265/12
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B60L3/0046
PERFORMING OPERATIONS; TRANSPORTING
F28D15/0283
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02T10/70
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
Y02E60/10
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F28D15/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B60L50/64
PERFORMING OPERATIONS; TRANSPORTING
Y10T29/49353
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
F28D15/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B60L3/00
PERFORMING OPERATIONS; TRANSPORTING
F28D15/06
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H01M10/6552
ELECTRICITY
Abstract
A battery module with one or more battery cells and a heat exchange member placed in thermal communication with the battery cell, and a method of making a heat pipe system from the heat exchange member. The heat exchange member includes a container with a heat transfer fluid disposed therein. In one form, the heat transfer fluid is capable of going through a phase change as a way to absorb at least a portion of heat present in or generated by battery cell. A pressure control device cooperates with the container and heat transfer fluid such that upon attainment of a predetermined thermal event within the battery cell, the pressure control device permits liberation of at least a portion of the heat transfer fluid to an ambient environment, thereby relieving pressure on the container and removing some of the excess heat caused by the thermal event.
Claims
1. A method of passively inhibiting propagation of a thermal event through a battery module, the method comprising: obtaining the battery module, the battery module including: a first cell configured to deliver a portion of an electric current; a second cell configured to deliver another portion of the electric current; a heat pipe disposed between the first cell and the second cell, the heat pipe having a first portion and a second portion, the first portion being disposed between the first cell and the second cell, the second portion being disposed in a protrusion extending from between the first cell and the second cell, the heat pipe defining a cavity, the cavity including an evaporation zone and a condensation zone, the evaporation zone corresponding to the first portion and the condensation zone corresponding to the second portion, the heat pipe being in thermal communication with the first cell and the second cell; a heat-transfer fluid disposed within the cavity, the heat-transfer fluid configured to undergo a phase change due to absorption of heat produced by at least one of the first cell and the second cell, the phase change increasing a pressure within the heat pipe; and a pressure-relief device coupled to the heat pipe, the pressure-relief device being actuated after the pressure within the heat pipe exceeds a predetermined level; moving, after occurrence of the thermal event in the first cell and via actuation of the pressure-relief device, latent heat from proximate the first cell to an external environment by removing at least a portion of the heat-transfer fluid from the cavity to produce a vented heat pipe; and inhibiting heat transfer between the first cell and the second cell using the vented heat pipe.
2. The method of claim 1, further comprising: evaporating the heat-transfer fluid at the evaporation zone to produce a vapor; transferring the vapor to the condensation zone; condensing the heat-transfer fluid at the condensation zone to produce a liquid; and returning the liquid to the evaporation zone using gravity.
3. The method of claim 1, wherein the first portion of the heat pipe has a cross-sectional outer profile that generally defines a rectangle.
4. The method of claim 1, wherein the first portion of the heat pipe is formed from a material having a high thermal conductivity.
5. The method of claim 1, further comprising cooling the second portion of the heat pipe using a cooling plate in thermal communication therewith.
6. The method of claim 1, wherein the pressure-relief device is a rupture disc.
7. The method of claim 1, wherein the pressure-relief device is a relief valve.
8. The method of claim 1, wherein the external environment is a free volume within the battery module.
9. The method of claim 8, wherein a first thermal conductivity of gasses in the free volume is lower than a second thermal conductivity of the heat-transfer fluid such that backfilling of the vented heat pipe increases insulating properties of the heat pipe.
10. A battery module comprising: a first cell configured to deliver a portion of an electric current; a second cell configured to deliver another portion of the electric current; a heat pipe disposed between the first cell and the second cell, the heat pipe having a first portion and a second portion, the first portion being disposed between the first cell and the second cell, the second portion being disposed in a protrusion extending from between the first cell and the second cell, the heat pipe defining a cavity, the cavity including an evaporation zone and a condensation zone, the evaporation zone corresponding to the first portion and the condensation zone corresponding to the second portion, and the heat pipe being in thermal communication with the first cell and the second cell; a heat-transfer fluid disposed within the cavity, the heat-transfer fluid configured to undergo a phase change due to absorption of heat produced by at least one of the first cell and the second cell, the phase change increasing a pressure within the heat pipe; and a pressure-relief device coupled to the heat pipe, the pressure-relief device being actuated after the pressure within the heat pipe exceeds a predetermined level, wherein the battery module is configured to passively move latent heat from proximate the first cell to an external environment after a thermal event by removing at least a portion of the heat-transfer fluid from the cavity to produce a vented heat pipe, and wherein the vented heat pipe is configured to inhibit propagation of the thermal event to the second cell by inhibiting heat transfer therebetween.
11. The battery module of claim 10, wherein movement of the heat-transfer fluid within the heat pipe includes moving the heat-transfer fluid as a liquid to the evaporation zone using gravity.
12. The battery module of claim 10, wherein the first portion of the heat pipe has a cross-sectional outer profile that generally defines a rectangle.
13. The battery module of claim 10, wherein the first portion of the heat pipe is formed from a material having a high thermal conductivity.
14. The battery module of claim 10, further comprising a cooling plate placed in thermal communication with the second portion of the heat pipe, the cooling plate being configured to cool the second portion of the heat pipe.
15. The battery module of claim 10, wherein the pressure-relief device is a rupture disc.
16. The battery module of claim 10, wherein the pressure-relief device is a relief valve.
17. The battery module of claim 10, wherein the portion of the heat-transfer fluid removed from the heat pipe is transferred to a free volume within the battery module.
18. A method of manufacturing a battery module including a heat pipe, the method comprising: obtaining the heat pipe including a housing including a plurality of threads, the housing defining a cavity having an open end; coupling a pressure-relief device to the open end of the cavity, the pressure-relief device generally sealing a volume within the cavity, the pressure-relief device configured to be actuated after a pressure within the cavity exceeds a first predetermined level; releasably securing the pressure-relief device with a removable fastener, the removable fastener being configured to inhibit actuation of the pressure-relief device after the pressure within the cavity exceeds the predetermined level; filling a portion of the volume with a heat-transfer fluid; affixing the heat pipe between a first battery cell and a second battery cell; and removing, after filling the portion of the volume with the heat-transfer fluid and after affixing the heat pipe, the removable fastener such that the pressure-relief device is actuated after the pressure within the cavity exceeds the predetermined level.
19. The method of claim 18, wherein the pressure-relief device is a rupture disc and the removable fastener is a set screw configured to engage the heat pipe, and wherein coupling the pressure-relief device to the open end of the cavity includes: placing the rupture disc proximate the open end of the cavity; abutting the rupture disc with the set screw; engaging the set screw with the plurality of threads of the housing; and rotating the set screw to engage the rupture disc with the heat pipe.
20. The method of claim 18, wherein filling a portion of the volume with the heat-transfer fluid occurs before affixing the heat pipe.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
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(10) As shown, the cooling plates 120 include heat pipes 122. It will be appreciated by those skilled in the art that the present depiction of the heat pipes 122 only at opposing edges of cooling plates 120 is merely exemplary, and that in one particular embodiment, the heat pipes 122 may be placed in a side-by-side manner across a substantial entirety of one or both major surfaces of each of plates 120, The use of an appropriate liquid within the heat pipes 122 promotes additional heat transfer through the selective evaporation and condensation of a small quantity of working fluid contained in an evacuated and sealed container that can take advantage of local variations in internal pressure of the fluid to allow respective absorption or release of latent heat. Acceptable heat transfer fluids for heat pipes include, but are not limited to, de-ionized water in a vacuum which can change from a liquid to gas phase, then re-condensing back to a liquid phase at the heat sink and transferring back to the heat source by use of gravity or a capillary system. The release of latent heat by means of a continuous phase transition cycle is known as a thermal siphon, and the heat transfer fluid can be tuned to the desired operating temperatures by either change in pressure or material composition. Preferably, gravity or capillary action allows fluid condensed at one end of the pipe 122 to move to the opposing end to be evaporated to allow the cycle to be repeated. As will be appreciated by those in the heat pipe art, when the fluid has a large heat of vaporization, a significant amount of heat can be transferred, even when the temperature differences between the opposing ends of the pipe 122 is not great. As stated above, heat transfer fluids may be used as a coolant in the heat pipe 122.
(11) It will be appreciated that other materials besides the presently-disclosed heat transfer fluids may be used to provide at least one of augmented heating or cooling to battery cells 110. For example, microPCM, which is made up of very small bi-component particles or capsules that include a core material that exhibits latent heat changes tailored to a temperature range typically countered in an automobile battery pack, along with an outer shell or capsule made from a polymer or related material such that together, the core and shell define a generally spherical foam-like material. An example of the use of microPCM in a battery thermal management system may be particularly suitable; such is discussed in more detail in co-pending U.S. patent application Ser. No. 13/175,225 entitled LIQUID COOLANT WITH MICROENCAPSULATED PHASE CHANGE MATERIALS FOR AUTOMOTIVE BATTERIES and filed on Jul. 1, 2011, which is owned by the Assignee of the present invention and hereby incorporated in its entirety by reference.
(12) In one preferred embodiment, a pressure control mechanism is situated in or on the heat pipes 122 to allow the fluid (particularly when in gaseous form) to vent; one such scenario where such a release would occur is where the temperature imparted to the heat pipes 122 is high enough to induce an overpressure situation within the pipe's sealed internal cavity. In such event, the released fluid would be introduced into either a free volume contained within the battery pack 10 or released to one or more specific locations, such as a void in the vehicle's engine bay. In another preferred embodiment, the heat pipe 122 housing or vessel is made from a high thermal conductivity material such that the housing acts in a manner generally similar to the aforementioned cooling fins. For example, the housing may be made from a high thermal conductivity metal, such as an aluminum-based or copper-based material.
(13) To achieve a desirable balance between battery life and performance, the present inventors have determined that only small temperature variations between the modules 100 of the pack 10 be permitted. Furthermore, the present inventors have determined that certain types of batteries, such as Li-Ion batteries, operate best at temperatures between 25 C. and 40 C., and that module-to-module differences be kept to no more than about 5 C. The heat pipes 122 can be designed for a specific operating temperature that satisfies the optimum battery cell 110; likewise, the relatively constant temperature of the heat pipes 122 helps improve the likelihood of relatively even cell 110 temperature distribution. One particular use of a heat pipe in conjunction with a lithium-ion battery is disclosed in more detail in co-pending U.S. patent application Ser. No. 12/914,062 entitled COMBINATION OF HEAT PIPE AND LOUVERED FINS FOR AIR-COOLING OF LI-ION BATTERY CELL AND PACK, which was filed on Jul. 1, 2011 and owned by the Assignee of the present invention; the entirety of such application is hereby incorporated by reference. A heat pipe such as heat pipe 122 is an example of a passive heat transfer element. In another example embodiment (not shown), the cooling element in the form of a heat pipe could be a smooth-faced prismatic container where the face of the cooling element is coincident with the face of a prismatic cell. An accordion-shaped structure would respond to pressure changes by having the volume of the cooling element expand through the stretching of the accordion-like folded metal.
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(21) It is noted that terms like preferably, commonly, and typically are not utilized herein to limit the scope of the claimed invention or to imply that certain features are critical, essential, or even important to the structure or function of the claimed invention. Rather, these terms are merely intended to highlight alternative or additional features that may or may not be utilized in a particular embodiment of the present invention. Likewise, terms such as substantially are utilized to represent the inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation. It is also utilized to represent the degree by which a quantitative representation may vary from a stated reference without resulting in a change in the basic function of the subject matter at issue.
(22) For the purposes of describing and defining the present invention it is noted that the term device is utilized herein to represent a combination of components and individual components, regardless of whether the components are combined with other components. For example, a device according to the present invention may comprise a source of motive power, a vehicle incorporating the source of motive power or other equipment that may make up, or be used in conjunction with, the vehicle or source of motive power. Furthermore, variations on the terms automobile, automotive, vehicular or the like are meant to be construed generically unless the context dictates otherwise. As such, reference to an automobile will be understood to cover cars, trucks, buses, motorcycles and other similar modes of transportation unless more particularly recited in context. Likewise, the invention may be used in conjunction with battery cells unrelated to automotive applications, where temperature-sensitive equipment may need added thermal protection; such additional configurations are understood as being within the scope of the present invention.
(23) Having described the invention in detail and by reference to specific embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims. More specifically, although some aspects of the present invention are identified herein as preferred or particularly advantageous, it is contemplated that the present invention is not necessarily limited to these preferred aspects of the invention.