US008273474B2

(12) United States Patent (10) Patent N0.: US 8,273,474 B2

Al-Hallaj et a]. (45) Date of Patent: *Sep. 25, 2012

(54) BATTERY SYSTEM THERMAL (56) References Cited

MANAGEMENT
U.S. PATENT DOCUMENTS
(75) Inventors: Said Al-Hallaj, Chicago, IL (US); Jan 3,780,356 A 12/1973 Laing
Robert Selman, Chicago, IL (US) 4,057,104 A 11/1977 AltoZ
4,329,407 A 5/1982 Gross et al.
4,332,866 A 6/1982 Jacquelin et al.
(73) Assignee: Illinois Institute of Technology, 4,389,533 A 6/1983 Ames
Chicago, IL (US) 4,413,157 A 11/1983 Ames
4,477,546 A 10/1984 Wheeler et al.
(*) Notice: Subject to any disclaimer, the term of this 4,629,622 A 12/1986 YoneZu et al.
patent is extended or adjusted under 35 4,650,727 A 3/1987 Vanderborgh et al.
4,883,726 A * 11/1989 Peled et al. ................. .. 429/120
U.S.C. 154(b) by 1106 days. 4,977,041 A 12/1990 ShioZaWa et al.
5,066,337 A 11/1991 Bhandari et a1.
This patent is subject to a terminal dis
claimer. (Continued)
FOREIGN PATENT DOCUMENTS
(21) Appl. N0.: 12/116,800
DE 42 30 583 3/1994
(22) Filed: May 7, 2008 (Continued)
(65) Prior Publication Data OTHER PUBLICATIONS

US 2009/0004556 A1 Jan. 1, 2009 Tanaka et a1.: Year 2000 R&D status of large-scale lithium ion sec
ondary batteries in the national project of Japan, Journal of Power
Related US. Application Data Sources 97-98 (2001), 2-6.

(63) Continuation-in-part of application No. 11/225,823, (Continued)

?led on Sep. 13, 2005, noW abandoned, Which is a Primary Examiner * Patrick Ryan
continuation of application No. 10/274,248, ?led on Assistant Examiner * Alex Usyatinsky
Oct. 18, 2002, noW Pat. No. 6,942,944, Which is a (74) Attorney, Agent, orFirm * Pauley Petersen & Erickson
continuation-in-part of application No. 09/515,268,
?led on Feb. 29, 2000, noW Pat. No. 6,468,689. (57) ABSTRACT
(60) Provisional application No. 60/928,188, ?led on May Electrochemical cell battery systems and associated methods
7, 2007. of operation are provided based on the incorporation of a
thermal management matrix including a supply of phase
change material disposed at least in part in a heat conductive
(51) Int. Cl.
lattice member to effectively dissipate heat produced or gen
H01M10/50 (2006.01)
erated by or in the battery system such as to minimize or
(52) US. Cl. ......................... .. 429/120; 429/62; 429/166
prevent thermal runaway propagation in the electrochemical
(58) Field of Classi?cation Search .................. .. 429/62,
cells of the system.
42 9/ 1 20, 1 66
See application ?le for complete search history. 20 Claims, 14 Drawing Sheets

430
 US 8,273,474 B2
Page 2

US. PATENT DOCUMENTS SpotnitZ et al.: Abuse behavior of high-power, lithium-ion cells,
5,071,652 A 12/1991 Jones et al. Journal ofPoWer Sources 113 (2003), pp. 81-100.
5,158,841 A 10/1992 Mennicke Yang et al.: Investigations of the Exothermic Reactions of Natural
5,224,356 A 7/1993 Colvin et al. Graphite Anode for Li-Ion Batteries during Thermal Runaway, Jour
5,272,491 A 12/1993 Asakawa et al. nal ofthe Electrochemical Society, 152 (1) (2005), pp. A73-A79.
5,285,559 A 2/1994 Thompson et al. Chen et al.: Modeling Studies on Battery Thermal Behaviour, Ther
5,326,656 A 7/1994 Meadows et al. mal Runaway, Thermal Management, and Energy Ef?ciency, IEEE
5,343,368 A 8/1994 Miller
5,353,867 A 10/1994 Jaspers (1996), pp. 1465-1470.
5,401,589 A 3/1995 Palmer et al. Saito et al.: Thermal behaviors of lithium-ion cells during over
5,405,718 A 4/1995 Hashemi charge, Journal ofPower Sources 97-98 (2001), pp. 693-696.
5,441,575 A 8/1995 Underwood et al. W.B. Gu et al.: Thermal-Electrochemical Coupled Modeling of a
5,441,824 A 8/1995 Rippel Lithium-Ion Cell, ECS Proceedings, vol. 99-25 (2000), pp. 748-762.
5,449,571 A 9/1995 Longardner et al. Hatchard et al.: Thermal Model of Cylindrical and Prismatic
5,505,788 A 4/1996 Dinwoodie Lithium-Ion Cells, Journal of the Electrochemical Society, 148 (7)
5,552,961 A 9/1996 Van Gaalet al.
5,557,208 A 9/1996 Parker (2001), pp. A755-A761.
5,593,792 A 1/1997 Farrier et al. Al Hallaj et al.: Thermal modeling and design considerations of
5,608,181 A 3/1997 Yasuda lithium-ion batteries, Journal ofPower Sources, 83 (1999) pp. 1-8.
5,614,332 A 3/1997 Pavelle et al. Jiang et al.: Thermal Stability of 18650 Size Li-Ion Cells Containing
5,871,859 A 2/1999 Parise LiBOB Electrolyte Salt, Journal ofthe Electrochemical Society, 151
5,895,728 A 4/1999 Walker et al. (4) (2004), pp. A609-A613.
6,033,800 A 3/2000 Ichiyanagi et al. Maleki et al.: Thermal Stability Studies of Li-Ion Cells and Compo
6,059,016 A 5/2000 Rafalovich
6,087,038 A 7/2000 Flament et al. nents, Journal of the Electrochemical Society, 146 (9) (1999), pp.
6,106,972 A 8/2000 Kokubo et al. 3224-3229.
6,140,266 A 10/2000 Corrigan et al. J. Robert Selman et al.: Active vs. Passive (PCM) Cooling Thermal
6,146,779 A 11/2000 Walsh Management of Li-ion Batteries, Poster Session, Advanced Automo
6,159,434 A 12/2000 Gonjo et al. tive Battery Conference, Long Beach, California, May 14-17, 2007,
6,203,948 B1 3/2001 Kao et al. 1 page.
6,220,337 B1 4/2001 Chen et al.
J. Robert Selman et al.: Active vs. Passive (PCM) Thermal Manage
6,245,462 B1 6/2001 Kao et al.
6,425,440 B1 7/2002 Tsenter et al. ment of Li-ion Batteries, Oral Presentation, Advanced Automotive
6,465,130 B1 10/2002 Numata et al. Battery Conference, Long Beach, California, May 14-17, 2007, 4
6,468,689 B1 10/2002 Hallaj et al. pages.
6,475,662 B1 11/2002 Spencer R. KiZilel et al.: Passive control of temperature excursion and uni
6,485,853 B1 11/2002 Pettit et al. formity in high-energy Li-ion battery packs at high current and ambi
6,570,362 B1 5/2003 Estes et al. ent temperature, Journal ofPower Sources, 183, (2008), pp. 370-375.
6,797,427 B2 9/2004 Maleki et al.
6,942,944 B2* 9/2005 Al-Hallaj et al. ........... .. 429/120
R. Sabbah et al.: Active (air-cooled) vs. passive (phase change mate
2001/0033961 A1 10/ 2001 Gudmundsson et al. rial) thermal management of high power lithium-ion packs: Limita
2002/0104645 A1 8/ 2002 Yoshida et al. tion of temperature rise and uniformity of temperature distribution,
2002/0136937 A1 9/ 2002 Kelley et al. Journal ofPoWer Sources, 182, (2008), pp. 630-638.
2002/0160237 A1 10/2002 Johnson J. Robert Selman et al.: Thermal modeling of Li-ion batteries with
2003/0020072 A1 1/2003 Higgins Active vs. passive cooling thermal management system, Powerpoint
2003/0044682 A1 3/2003 Park et al. Presentation, 211th Electrochemical Society Meeting, Chicago, Illi
2003/0066638 A1 4/2003 Qu et al.
nois, May 7-10, 2007, 26 pages.
FOREIGN PATENT DOCUMENTS R. KiZilel et al.: Prevention of Thermal Runaway Propagation in a
GB 2289976 6/1995
Li-Ion Battery Pack, Presentation VPPC-07, Arlington, TX, Sep.
JP 58 166679 10/1983 9-12, 2007, 15 pages.
JP 358166679 10/1983 R. KiZilel et al.: Prevention of Thermal Runaway Propagation in a
JP 61218072 9/1986 Li-Ion Battery Pack, Presentation, VPPC-07, Arlington, TX., Sep.
JP 09 270263 10/1997 9-12, 2007, 3 pages.
J. Robert Selman et al.: Active (air-cooled) / Passive (PCM) Thermal
OTHER PUBLICATIONS Management of Large Li-ion Batteries: key requriements and fea
tures, Taipei Forum Large-Format Li-ion Batteries, Jan. 31-Feb. 1,
Mills et al.: Thermal conductivity enhancement of phase change
2008, 26 pages.
materials using a graphite matrix, Applied Thermal Engineering 26
(2006), pp. 1652-1661. * cited by examiner
US. Patent Sep. 25, 2012 Sheet 1 0f 14 US 8,273,474 B2

FIG. 1
US. Patent Sep. 25, 2012 Sheet 2 0f 14 US 8,273,474 B2

FIG. 2 FIG. 3

EYE
\ H /,
5 )0 (\52
FIG. 4
US. Patent Sep. 25, 2012 Sheet 3 0f 14 US 8,273,474 B2

1.0

0 75

05

DOD=O.25

DISTANCE (cm)

FIG. 5
US. Patent Sep. 25, 2012 Sheet 4 0f 14 US 8,273,474 B2

1.0
g :
Lu 30.0
(f) _

? _
DC _

2
L,_, 20 0
m -1

E _
g _
o. _ 0.5
5 10.0—
H 1.} DOD=O.25 U I
J1 ‘\J *1
0.0
l I I I I I I I I l r I I I I

0.0 5.0 10.0 15.0

DISTANCE (cm)

FIG. 6
US. Patent Sep. 25, 2012 Sheet 5 0f 14 US 8,273,474 B2

1 0.

253E52i w 0.
m
0 5.
DOD=0.25 T

0.0
0.0
DISTANCE (cm)

FIG. 7
US. Patent Sep. 25, 2012 Sheet 6 0f 14 US 8,273,474 B2

1.0

0 75

2@$5310;5 05

DOD=0.25

0.0 5.0
DISTANCE (cm)

FIG. 8
US. Patent Sep. 25, 2012 Sheet 7 0f 14 US 8,273,474 B2

mh-

2@ma5?1 ;5 64.2

O00.
DO nI8 m
$2
.2! mmm__

_0-
SQ“50. .

4 _
I
L

D
J
in0
I0. l0
1 0. 1 IS
DISTANCE (cm)

FIG. 9
US. Patent Sep. 25, 2012 Sheet 8 0f 14 US 8,273,474 B2

FIG. 10
US. Patent Sep. 25, 2012 Sheet 9 0f 14 US 8,273,474 B2

FIG. 1 1
US. Patent Sep. 25, 2012 Sheet 10 0f 14 US 8,273,474 B2

210

212 214

216

FIG. 12
US. Patent Sep. 25,2012 Sheet 11 or 14 US 8,273,474 B2

FIG. 13
US. Patent Sep. 25,2012 Sheet 12 or 14 US 8,273,474 B2

410 420 6

414

FIG. 15
US. Patent Sep. 25, 2012 Sheet 13 0f 14 US 8,273,474 B2
US. Patent Sep. 25,2012 Sheet 14 or 14 US 8,273,474 B2

Propagation of Thermal Runaway in a pack

without PCM Cooling

t=1200 sec

FIG. 18

M100

’mn
so (-0
" sec t=10 sec
'
-
t=20 SEC

0 -- -
‘_ 5° t=40 sec t=60 sec (=80 Sec

2
Wt 200

FIG. 19
 US 8,273,474 B2
1 2
BATTERY SYSTEM THERMAL In practice, temperature variations betWeen individual
MANAGEMENT cells can result from one or more of a variety of different
factors including, for example:
CROSS REFERENCE TO RELATED 1) changes in ambient temperature;
APPLICATION 2) unequal impedance distribution among cells and
3) differences in heat transfer ef?ciencies among cells.
This application claims the bene?t of US. Provisional Differences in heat transfer ef?ciencies among cells can typi
Application No. 60/928,188, ?led 7 May 2007. This applica cally be primarily attributed to the cell pack con?guration.
tion also is a continuation-in-part of US. application Ser. No. For example, cell elements at the center of a module or cell
pack con?guration may tend to accumulate heat While those
11/225,823, ?led on 13 Sep. 2005 noW abandoned Which is a
cell elements at the periphery of the module or cell pack
continuation of US. application Ser. No. 10/274,248, ?led on
con?guration Will generally tend to be more easily or freely
18 Oct. 2002, now US. Pat. No. 6,942,944, issued 13 Sep. cooled as a result of greater relative heat transfer to the sur
2005, Which is a continuation-in-part of US. application Ser. rounding environment. Further, such variation in heat transfer
No. 09/515,268, ?led on 29 Feb. 2000, now US. Pat. No. ef?ciencies may lead to further differences in impedance such
6,468,689, issued 22 Oct. 2002. The co-pending U.S. Provi as may serve to amplify capacity differences among the cells.
sional Application; US. application Ser. No. 11/225,823, Such capacity imbalances can cause or result in some cells
?led on 13 Sep. 2005; US. application Ser. No. 10/274,248, being over-charged or over-discharged Which in turn may
?led on 18 Oct. 2002, now US. Pat. No. 6,942,944, issued 13 result in premature failure of a speci?c cell element or of an
Sep. 2005; and US. application Ser. No. 09/515,268, ?led on 20 associated cell pack or module. In particular, such failures
29 Feb. 2000, now US. Pat. No. 6,468,689, issued 22 Oct. may take the form of thermal runaWay or accelerating capac
2002 are hereby incorporated by reference herein and made a ity fading.
part hereof, including but not limited to those portions Which Thermal management systems based on the use of active
speci?cally appear hereinafter. cooling (e.g., such as based on forced circulation of air, liquid
25 or other selected cooling medium) have been proposed foruse
BACKGROUND OF THE INVENTION in conjunction With such battery poWer supply systems. Spe
ci?c forms or types of active cooling include: “intemal active
This invention relates generally to battery poWer supply cooling” Wherein a selected cooling medium is typically cir
and, more particularly, to thermal management in such bat culated internally Within the battery module or pack and
tery poWer supply systems. The Word “battery” here is meant 30 “external active cooling” Wherein a selected cooling medium
to include various forms of electrochemical poWer generation is typically circulated externally to the battery module. It Will
Which have in common that chemical energy, in the form of be appreciated, hoWever, that the incorporation and use of
one or more chemical reactants stored in a con?ned space,
internal active cooling regimes may introduce an undesired
react With each other or With an external reactant in an elec
level of complexity in either or both poWer supply design and
35 operation and such as may hinder or prevent the more Wide
trochemical reaction, so as to produce electric poWer When
spread use of such corresponding poWer supply systems.
desired.
Further, the required or desired siZe of a battery poWer
Various uses of battery poWer supplies have been Well supply is generally dependent on the speci?c application
established. For example, the packaging together of a plural thereof. Thus, certain contemplated or envisioned applica
ity of cells in a parallel or series con?guration to form a 40 tions for such poWer supplies, such as to poWer electric
battery module or pack for use as a poWer supply for personal vehicles, for example, may necessitate the use of such poWer
electronic devices such as cell phones, lap top computers, supplies Which have or are of signi?cantly larger physical
camcorders or the like have become Well-knoWn and com dimensions than those presently commonly used or available.
mon. In addition, desirable properties or characteristics of As Will be appreciated by those skilled in the art, thermal
battery poWer supplies including, for example, the capability 45 management in poWer supply systems can become even more
of certain battery poWer supplies to be recharged makes such critical or signi?cant as the siZe of such cell, battery module,
battery poWer supplies an attractive potential poWer source or battery pack is increased.
for vehicle propulsion, i.e., electric vehicles (EV). Recently, Thus, there is a need and a demand for neW and improved
the concept as Well as the application of battery poWer have poWer supply systems and methods of operation Whichpermit
been extended to include “fuel batteries” or “fuel cell batter 50 either or both more e?icient and effective thermal manage
ies”, in Which a fuel cell reaction is used to generate electric ment. In particular, there is a need and a demand for such
poWer in a manner someWhat similar to that of a conventional poWer supply systems and methods of operation Which desir
rechargeable battery, but in Which one of the reactants (the ably avoid the potential complications and complexities of
fuel) must be replenished from time to time. typically contemplated internal active cooling thermal man
In various such applications, it is common that a number of 55 agement systems. Further, there is a need and a demand for a
cells are packed together in a preselected con?guration (e.g., Well designed thermal management system such as can desir
in parallel or in series) to form a battery module. A number of ably better ensure one or more of the performance, safety or
such battery modules may, in turn, be combined or joined to capacity of an associated poWer supply.
form various battery packs such as are knoWn in the art. Improved battery design has resulted in increased potential
During operation and discharge, such cells, battery modules 60 applications for batteries. For example, lithium-ion (Li-ion)
or battery packs commonly produce or generate quantities of batteries are presently considered a preferred choice for next
heat Which can signi?cantly detrimentally impact the perfor generation hybrid vehicles, especially plug-in hybrid
mance that results therefrom. Thus, in order to maintain vehicles. Li-Ion battery packs have a potentially poWerful
desired or optimal performance by such cells or resulting advantage in being compact compared to nickel-metal
battery modules or battery packs, it is generally important to 65 hydride batter packs. Such compact and poWer dense Li-Ion
maintain the temperature of such cells, battery modules or battery packs, hoWever, give rise to system design challenges
battery packs Within fairly narroW prescribed ranges. such as hoW to most effectively and e?iciently: 1) dissipate
 US 8,273,474 B2
3 4
heat in a compact geometry; 2) maintain temperature unifor The invention further comprehends a method of operating
mity for safe and effective operation; and 3) guard against a power supply system. In accordance with one embodiment
thermal runaway or otherwise deal with safety issues due to of the invention, such a method includes discharging at least
potential for overheating. one cell element to produce a quantity of power and a quantity
As used herein, references to “thermal runaway” generally of heat. Alternatively, the charging of at least one cell element
refer to the sudden, rapid increase in cell temperature and may similarly produce a quantity of heat. At least a portion of
pressure due various operational factors and which in turn can the quantity of heat is absorbed in a phase change material in
lead to propagation of excessive temperature throughout an thermal contact with the discharging cell element. Such
associated module. Potential causes for thermal runaway in method further includes subsequently releasing at least a
such systems may, for example, include: cell defects and/or portion of the absorbed quantity of heat from the phase
change material to heat the at least one cell element.
short circuits (both internal and external), overcharge, cell In accordance with another embodiment, the invention
puncture or rupture such as in the event of an accident, and
provides a battery module which includes a housing and a
excessive ambient temperatures (e. g., temperatures typically plurality of electrochemical cell elements, capable of a heat
greater than 55° C.). In normal use, the cells heat as result of generating charge, contained within the housing. The battery
internal resistance. Under normal power/current loads and module also includes a supply of a phase change material. The
ambient operating conditions, the temperature within most phase change material is contained within the housing in
Li-ion cells can be relatively easily controlled to remain in a thermal contact with at least one of the plurality of electro
range of 200 C. to 55° C. However, stressful conditions such chemical cell elements whereby the phase change material
as high power draw at high cell/ ambient temperatures, as well 20 absorbs at least a portion of the heat generated upon a charge
as defects in individual cells, may steeply increase local heat or discharge of electric power from the at least one of the
generation. In particular, above the critical temperature, exo plurality of electrochemical cell elements. The battery mod
thermic chemical reactions within the cell are activated. ule further includes a heat-conductive containment lattice
Moreover, chemical heat generation typically increases expo member also contained within the housing. The containment
nential with temperature. As a result, heat generation 25 lattice member has a plurality of openings wherein at least a
becomes much greater than available heat dissipation. Ther portion of the supply of the phase change material is disposed.
mal runaway can lead to cell venting and internal tempera The invention also comprehends a method of operating a
tures in excess of 2000 C. power supply system. In accordance with one embodiment of
Exothermic reactions as a result of the electrolyte oxida the invention, such a method includes discharging at least one
tion by the cathode and the combustion reactions based on the 30 cell element of a battery module to produce a quantity of
released oxygen from the cathode can cause serious safety power and a quantity of heat. At least a portion of the quantity
concerns for Li-ion batteries and hence limit Li-ion battery of heat is absorbed in a phase change material in thermal
applications and viability. In particular, these chemical reac contact with the discharging cell element with the phase
tions may form hot spots inside a cell and lead to thermal change material disposed in a plurality of openings in a heat
runaway. 35 conductive containment lattice member. Following dis
This may lead to thermal runaway of some cells and/or charge, at least a portion of the absorbed quantity of heat is
propagation of exces sive temperature throughout the module. released from the phase change material to heat the at least
Therefore, improved or increased thermal management to one cell element to a greater than ambient temperature. The
minimize or desirably prevent such thermal runaway propa heated at least one cell element is itself subsequently dis
gation within such battery systems, particularly without 40 charged.
requiring over-design of the cooling system and complicating In another aspect there is provided a battery system that
system control, is desired and sought. includes an electrochemical cell array including a plurality of
electrochemical cell elements. The battery system also
SUMMARY OF THE INVENTION includes a thermal management matrix at least in part envel
45 oping the electrochemical cell array and in thermal contact
A general obj ect of the invention is to provide an improved therewith. The thermal management matrix includes a supply
power supply system and method of operation. of phase change material disposed at least in part in a heat
A more speci?c objective of the invention is to overcome conductive lattice member. The thermal management matrix
one or more of the problems described above. dissipates at least a portion of heat generated upon activation
The general object of the invention can be attained, at least 50 of at least a portion of the electrochemical cell array envel
in part and in accordance with one embodiment of the inven oped by the thermal management matrix
tion, through a power supply system which includes at least In another embodiment there is provided a thermally man
one cell element capable of a heat-generating charge or dis aged lithium-based battery system. The system includes an
charge of electric power and a supply of phase change mate electrochemical cell array composed of a plurality of lithium
rial in thermal contact with the at least one cell element 55 based electrochemical cell elements and a thermal manage
whereby the phase change material absorbs at least a portion ment matrix at least in part in thermal contact with at least one
of the heat generated upon a discharge of power from the at of the lithium-based electrochemical cell elements of the
least one cell element. electrochemical cell array. The thermal management matrix
The prior art generally fails to provide a power supply includes a supply of phase change material. At least a portion
system and method of operation which provides or results in 60 of the supply of phase change material is disposed in a heat
thermal management which is either or both as effective and conductive lattice member.
e?icient as may be desired. Further, the prior art generally Another aspect relates to a method of avoiding thermal
fails to provide power supply system thermal management runaway propagation in an electrochemical cell array com
and operation such as may more conveniently or effectively prising a plurality of electrochemical cell elements. In accor
permit the use of larger-sized battery power supplies such as 65 dance with one embodiment, such a method involves dissi
contemplated or envisioned for certain applications, such as pating heat produced by at least a ?rst electrochemical cell
to power electric vehicles, for example. element of the electrochemical cell array at least in part via a
 US 8,273,474 B2
5 6
thermal management matrix at least in part enveloping at least tem and method of operation such that provide or result in
the ?rst and a second electrochemical cell elements of the improved thermal management such as Wherein undesired
electrochemical cell array. The thermal management matrix temperature excursions and non-uniformity of temperature
includes a supply of phase change material at least in part can be appropriately reduced, minimiZed or otherWise suit
disposed in a heat conductive lattice member. The heat is ably managed.
dissipated to at least one of the phase change material, the The present invention may be embodied in a variety of
second electrochemical cell element and combinations different structures. As representative, FIG. 1 illustrates the
thereof. present invention as embodied in a battery module, generally
Other objects and advantages Will be apparent to those designated by the reference numeral 10. The battery module
skilled in the art from the folloWing detailed description taken 10 includes a cell package 12 composed of eight (8) cell
in conjunction With the appended claims and draWings. elements 14, 16, 18, 20, 22, 24, 26 and 28 such as knoWninthe
art.
BRIEF DESCRIPTION OF THE DRAWINGS FIG. 2 illustrates the cell element 14 in isolation and in
greater detail. As shoWn, the cell element 14 has a generally
FIG. 1 is a top vieW schematic of a battery module incor cylindrical shape composed of a length L and a Width D.
porating a thermal management system in accordance With While such shaped cell elements are common and Well
one embodiment of the invention. knoWn, the broader practice of the invention is not necessarily
FIG. 2 is a perspective schematic of a cell element used in so limited as cell elements having other desired shapes or
the battery module shoWn in FIG. 1. siZes can, if desired, be used alone or in combination.
FIG. 3 is a perspective schematic of the cell elements used 20 FIG. 3 illustrates the cell package 12 in isolation and in
in the battery module shoWn in FIG. 1. greater detail.
FIG. 4 is a top vieW schematic of a comer of the simulated Returning to FIG. 1, the battery module 10 forms or
battery module shoWing tWo cells out of eight total cells in the includes void spaces, generally designated by the reference
module. numeral 32, betWeen the various adjacent cell elements 14,
FIGS. 5-8 are graphical representations of the temperature 25 16, 18, 20, 22, 24, 26 and 28 ofthe cell package 12.
pro?le across the comer of the battery module, shoWn in FIG. In accordance With a preferred practice of the invention,
4, during discharge at selected discharge rates and at various such battery module voids are ?lled or otherWise appropri
selected Depths of Discharge (DOD). ately contain a suitable phase change material (PCM), gen
FIG. 9 is a graphical representation of the temperature erally designated by the reference numeral 34 and such as
pro?le across the comer of the battery module, shoWn in FIG. 30 described in greater detail beloW, such as to facilitate desired
4, at selected points in time during relaxation. thermal management Within such a poWer supply system. In
FIG. 10 is a top vieW schematic of a battery module incor particular, in the illustrated embodiment, the phase change
porating a thermal management system in accordance With material 34 surrounds each of the cell elements 14, 16, 18, 20,
another embodiment of the invention. 22, 24, 26 and 28, and is in general thermal contact thereWith.
FIG. 11 is a top vieW schematic of a speci?ed quadrant of 35 In accordance With one preferred embodiment of the inven
the battery module shoWn in FIG. 10. tion, the so included or incorporated phase change material 34
FIG. 12 is a top vieW schematic of a battery module quad can desirably serve or act as a heat sink to absorb excess heat
rant, similar to that shoWn in FIG. 10 but noW of a battery generated Within the module 10 such as during the relatively
module in accordance With another embodiment of the inven highly exothermic process of battery discharge or charge. In
tion. 40 particular, the heat generated from the cells 14, 16, 18, 20, 22,
FIG. 13 is also a top vieW schematic of a battery module 24, 26 and 28 during discharge can be stored, at least tempo
quadrant, similar to that shoWn in FIG. 10 but noW of yet rarily in the phase change material 34 as latent heat.
another battery module in accordance With the invention. Thus, the phase change material 34 permits the storage of
FIG. 14 is a perspective vieW of a Li-ion cell and thermal such heat for later or subsequent use or utiliZation. For
management matrix-containing battery module in accor 45 example, the heat stored or otherWise contained Within such
dance With one aspect of the invention. phase change material can later be appropriately released or,
FIG. 15 is a perspective vieW of a battery pack in accor as commonly referred to, “rejected” for appropriate use in or
dance With one aspect of the invention. in conjunction With the battery module 10. In particular, such
FIG. 16 is a perspective vieW of the thermal management stored heat can be appropriately rejected to the cell module
matrix of the battery module shoWn in FIG. 14, noW in iso 50 during relaxation and keep the cells at an elevated tempera
lation. ture above the surrounding temperature for an extended
FIG. 17 is a perspective vieW of a thermal management period of time. For example, such heat can be later rejected
matrix in isolation and in accordance With another embodi such as When the battery temperature drops such as during
ment. battery charge or under cold Weather conditions.
FIG. 18 illustrates propagation of thermal runaWay in a 55 Various phase change materials, such as knoWn in the art,
pack of cells Without the inclusion of a thermal management can suitably be used in the practice of the invention. For
matrix in accordance With the invention. example, suitable phase change materials for use in Li-ion
FIG. 19 illustrates prevention of propagation of thermal battery applications desirably Will have a melting point in the
runaWay in a pack of cells via the inclusion of a thermal range of betWeen about 30° C. and 60° C., a high latent heat
management matrix in accordance With one embodiment of 60 per unit mass ratio, and a narroW melting temperature range.
the invention. Further, phase change materials for use in the practice of the
invention Will also desirably be thermally cyclable, non-haZ
DETAILED DESCRIPTION OF THE INVENTION ardous, non-contaminant, non-reactive or otherWise inert
With respect to other battery components, nontoxic, cheap
The present invention generally provides an improved 65 and of relatively light Weight or density. Thus, suitable such
poWer supply system and method of operation. More particu phase change materials may generally include para?in Waxes
larly, the invention provides an improved poWer supply sys such as are relatively inexpensive, not easily or prone to
 US 8,273,474 B2
7 8
decomposition and Which generally have a relatively loW TABLE 1-continued
melting temperature Within the recommended range of opera
tion for Li-ion cells. Physical Properties of the Paraf?n Wax
Used in the Simulation
Alternatively, those skilled in the art and guided by the
teachings herein provided Will appreciate that chlorobenZene Property Value
and bromobenZene crystallize With very similar structure and Melting Temperature 560 C.
have a low and narroW temperature range of crystallization. CP (melted Wax) 1770 J - kg’l - K’1
Thus, mixtures of chlorobenZene and bromobenZene may be C}, (solid Wax) 1770 J - kg’l - K’1
suitable for particular applications such as involving precise k (melt Wax) 0.21 W - In’l - K’1
k (solid Wax) 0.29 W - In’l - K’l
temperature control betWeen about 30° C. to about 45° C., for Latent heat of fusion 195 kJ - kg’l
example.
Other possible or suitable phase change materials for such
applications may include stearic acid Which has a melting A commercial tWo-dimensional ?nite element (FE) soft
point of about 70° C., and various commercially available Ware program called PDEase2DTM by Macsyma Inc. Was
used to simulate the thermal behavior of the battery pack.
esters of stearic acid With methyl, propyl and butyl alcohols,
having melting points in the range of about 17° C. to about 34° Results and Discussion
C. Another candidate phase change material for use in the FIGS. 5-8 are graphical representations of the temperature
practice of the invention is polyethylene glycol (PEG). Poten pro?le across the comer 42 of the battery module 40, shoWn
tial or possible problems or concerns With thermal degrada in FIG. 4, during discharge at selected discharge rates (C/ 1,
20
tion by or of PEG may, hoWever, prevent, limit or otherWise C/2, C/3 and C/ 6, respectively, and each under a heat transfer
restrict such use or application. In vieW of the above, it is to be coe?icient, h:6.4 W~m_2~K_l, Which generally corresponds
understood that the broader practice of the invention is not to the natural cooling rate, that is Without active cooling) and
necessarily limited or restricted to the use of or the practice in at various selected Depths of Discharge (DOD). Results for
conjunction With speci?c or particular phase change materi 25 the other three comer cell pairs are assumed to be the same
als. because of module symmetry.
The present invention is described in further detail in con As shoWn in FIG. 5, the temperature rise at the center of
nection With the folloWing examples Which illustrate or simu both of the cells 44 and 46, at the end of discharge, is 53 K,
late various aspects involved in the practice of the invention. While a temperature rise of only 1 1 K is realiZed for the PCM
It is to be understood that all changes that come Within the 30 material. The temperature difference betWeen the surface and
spirit of the invention are desired to be protected and thus the the center of each of the cells is less than 2 K, at all DOD. The
invention is not to be construed as limited by these examples. loWer temperature rise in the phase change material is attrib
utable to the latent heat of phase change Which the phase
EXAMPLES
change material undergoes. That is, most of the heat rejected
35 by the module cells during discharge is stored as latent heat in
For purposes of these simulation examples, a rechargeable
battery module composed of eight (8) scaled-up prototype the associated phase change material by changing the phase
cells connected in series and similar in arrangement to the of this material, or a portion thereof, from solid to liquid. This
battery module 10 shoWn in FIG. 1 is assumed. This simu stored heat can subsequently be released after the end of
lated battery module, generally designated by the reference discharge such as during the time the cell is left to relax.
40
numeral 40 and, speci?cally a corner 42 thereof Which con Similar results are found for the other discharge rates, as
tains tWo cells (individually designated by the reference shoWn in FIGS. 6-8. The temperature rise at the center of both
numeral 44 and 46, respectively) out of eight total cells is of the cells 44 and 46, at the end of discharge for the sloWer
shoWn in FIG. 4. As Will be appreciated, the corner pair of C/2, C/3 and C/6 discharge rates, are 34 K, 29 K and 24 K,
cells 44 and 46 generally correspond to any of the cornerpairs 45 respectively. Thus, as those skilled in the art and guided by the
ofcells, e.g., 14 and 16; 18 and 20; 22 and 24; and 26 and 28, teachings herein provided Will appreciate, discharge at a
shoWn in FIGS. 1 and 3. faster or greater rate generally results in increased heat gen
It is further assumed that the scaled-up prototype cells of eration and can thus heighten or increase the need for effec
Which the simulated battery module 40 is composed have the tive thermal management such as realiZable With the imple
same chemistry as a knoWn cell for Which thermophysical 50 mentation of the invention.
properties and heat generation rates per unit volume have FIG. 9 is a graphical representation of the temperature
previously been measured and can be used as inputs. pro?le across the comer 42 of the battery module 40, shoWn
The voids 50 betWeen the module cells 44 and 46 are, in in FIG. 4, at selected points in time during relaxation. As
accordance With the invention, assumed to be ?lled With a shoWn, after 24 hours of relaxation, the temperature of each of
phase change material 52 such as to overcome anticipated 55 the cells 44 and 46 Was almost 10 K higher than the initial
overheating problems. For purposes of these simulation (surrounding) temperature. As Will be appreciated, such per
examples, a para?in Wax phase change material having the formance can have signi?cant design and use implications.
physical properties identi?ed in TABLE 1 beloW is assumed. For example, it has been shoWn that the utiliZed capacity of
the Li-ion batteries is strongly dependent on temperature,
TABLE 1 60 especially at loW operating temperatures. Thus, the utiliZed
Physical Properties of the Paraf?n Wax capacity of a corresponding battery can be signi?cantly
Used in the Simulation increased by elevating the cell temperature during operation.
As another example, the performance of fuel batteries (fuel
Property Value cell batteries) such as utiliZing hydrogen or methanol fuel and
Density ofrnelted Wax 822 kg - In’3 65 operating With state-of-the-art solid polymer electrolyte has
Density ofthe solid Wax 910 kg - In’3 been shoWn to deteriorate severely beyond a certain maxi
mum temperature. Therefore, rapid removal of heat devel