The Impact of a Combined Battery Thermal Management and Safety System Utilizing Polymer Mini-Channel Cold Plates on the Thermal Runaway and Its Propagation
Abstract
:1. Introduction
- Is there a difference in battery cell behavior between thermally conditioned and non-conditioned cells when subjected to overcharge-induced TR up to the cell fire? Is there a significant temporal impact on the process chain recognizable, especially before the TR and cell fire?
- Which heat dissipation rate is achievable using the polymer mini-channel cold plates?
- If the TR and cell fire are reached, is there a detectable preventive influence of the polymer cold plates on TRP to the adjacent cells?
2. Theory
2.1. Overcharge-Induced Thermal Runaway
2.2. Cold Plate Thermal Management
3. Materials and Methods
3.1. Battery Cell
3.2. Polymer Mini-Channel Cold Plates
3.3. Experimental Design
3.3.1. Structure of the Battery Assembly
3.3.2. Experimental Setup and Procedure
3.3.3. Measurement Plan
4. Results and Discussion
4.1. Overcharging without Thermal Conditioning
4.1.1. Temperature and Voltage Characteristics
4.1.2. Visualization of the Cell Fire
4.1.3. Evaluation of the Results
4.2. Overcharging with Thermal Conditioning
4.2.1. Temperature and Voltage Characteristics and Comparison
4.2.2. Evaluation of Results and Comparison
4.3. Overcharging with Malfunctioning Thermal Management
4.3.1. Temperature and Voltage Characteristics
4.3.2. Visualization of the Cell Fire with Thermal Management and Safety System
4.3.3. Impact of Polymer-Based Cold Plates as Thermal Barriers
4.4. Performance of the MCHS
5. Conclusions
6. Outlook
Author Contributions
Funding
Data Availability Statement
Acknowledgments
Conflicts of Interest
Nomenclature
Symbol | Name | Unit |
Area | m2 | |
Heat capacity | J/kg K | |
Current | A | |
Thermal conductivity | W/m K | |
length | m | |
Mass flow rate | kg/m3 | |
Time | s | |
Temperature | K | |
Electric charge | Ah | |
Heat | J | |
Heat flow rate | W | |
Electric resistance | ||
Open circuit voltage | V | |
Electric voltage | V |
Subscripts
DC | Direct current |
eff | effective |
el | electric |
Fluid,in | Fluid inlet |
Fluid,out | Fluid outlet |
i | internal |
irrev | irreversible |
layer,j | layer number j |
OCV | Open Circuit Voltage |
rev | reversible |
parallel | |
⊥ | perpendicular |
Abbreviation
Exp. | Experimental |
Ind. | Induction |
Max. | Maximum |
Num. | Numerical |
OC | Overcharged |
Std. dev. | Standard deviation |
Temp. | Temperature |
Acronyms
ABS | Acrylonitrile butadiene styrene |
CC | Constant Current |
CCCV | Constant Current Constant Voltage |
BEV | Battery electric vehicle |
BTMS | Battery thermal management system |
EIS | Electrochemical Impedance Spectroscopy |
EUCAR | European Council for Automotive Research & Development |
FT-IR | Fourier Transform-Infrared Spectrometer |
MCHS | Mini-channel heat sink or heat source |
NMC | Nickel-Manganese-Cobalt |
OVGU | Otto-von-Guericke University |
PCM | Phase Change Material |
SEI | Solid Electrolyte Interphase |
SOC | State of charge |
TCs | Thermocouples |
TIM | Thermal Interface Material |
TPS | Transient Plane Source |
TR | Thermal runaway |
TRP | Thermal runaway propagation |
Appendix A
Appendix A.1. Equations
Appendix A.2. Figures and Tables
Exp. | Ambient Temp. | Non-Linear Increase of Voltage/ Begin Stage II | Voltage Drop/ Begin Stage IV | TR/ Begin Stage V | Duration from Voltage Increase to Drop/ Stages II + III | Duration from Voltage Drop to TR/ Stage IV | |||||||
---|---|---|---|---|---|---|---|---|---|---|---|---|---|
(°C) | (V) | Time (min) | SOC (%) | Upper (V) | Lower (V) | Diff. (V) | Time (min) | SOC (%) | Time (min) | SOC (%) | Time (min) | Time (min) | |
#1 | 8 | 4.89 | 30.1 | 150 | 7.22 | 6.05 | 1.17 | 46.7 | 178 | 49.7 | 183 | 16.6 | 3.0 |
#2 | 10 | 4.89 | 27.8 | 146 | 6.25 | 5.25 | 1.00 | 43.7 | 173 | 50.0 | 183 | 15.9 | 6.3 |
#3 | 8 | 4.85 | 26.1 | 143 | 6.84 | 5.93 | 0.91 | 43.8 | 173 | 45.0 | 175 | 17.7 | 1.2 |
#4 | 10 | 4.96 | 24.8 | 141 | 8.33 | 6.91 | 1.42 | 39.0 | 165 | 40.5 | 168 | 14.2 | 1.5 |
#5 | 12 | 4.91 | 26.4 | 144 | 5.77 | 5.28 | 0.49 | 42.5 | 171 | 50.0 | 183 | 16.1 | 7.5 |
#6 | 11 | 4.80 | 29.1 | 149 | 6.83 | 6.23 | 0.60 | 40.6 | 168 | 41.7 | 170 | 11.5 | 1.1 |
#7 | 14 | 4.86 | 29.2 | 149 | 8.52 | 6.08 | 2.44 | 45.2 | 175 | 46.5 | 178 | 16.0 | 1.3 |
#8 | 10 | 4.88 | 25.3 | 142 | 6.51 | 5.69 | 0.82 | 44.0 | 173 | 50.3 | 184 | 18.7 | 6.3 |
#9 | 7 | 4.76 | 24.3 | 140 | 6.17 | 5.43 | 0.74 | 43.2 | 172 | 55.2 | 192 | 18.9 | 12.0 |
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Source/ Year | Type of Examination | Type of Cell/ Configuration | Type of BTMS | Findings |
---|---|---|---|---|
[37]/ 2022 | Num./exp., Cycling/cooling | Pouch, 10 Ah/ module | Direct cooling by immersion, ABS micro-channel plates as flow separator/ turbulator between cells | Micro-channel plate improves cooling performance in narrow space by reducing the temperature gradient in the system |
[38]/ 2021 | Num./exp., TR ind./cooling | Prismatic, 37 Ah/ module | Indirect bottom cooling by aluminum mini-channel cold plate and insulation by aerogel layers between cells | Singular liquid cooling or insulation fails to mitigate TRP; coupling of cooling and insulating with 1 mm layers avoids TRP |
[39]/ 2021 | Num./exp., Cycling and TR ind./cooling | Prismatic, 25 Ah/ array of two cells | Indirect cooling aluminum plate-fin and fluid cooling channels, embedded in PCM layer between cells | Cycling: coupled cooling results in more uniform temperatures than singular techniques; TRP: induction by overheating only prevented by coupled cooling, not by singular techniques; PCM of high thermal conductivity lowers system temperature but increases TRP probability |
[40]/ 2021 | Num./exp., Cycling/cooling | 18650 Cylindrical, Unknown cell capacity/ 50 Ah pack | Indirect cooling by polymer macro-channel tubes, connected at one side with the cells | Heat dissipation requirements met at low discharge rates; <5 °C temperature gradient in the system up to 2 C |
[41]/ 2019 | Num., TR ind./cooling | 18650 Cylindrical, 1.5 Ah/ module | Indirect cooling by aluminum micro-channel cold plates embedded in a PCM matrix between battery rows | TRP induced by nail penetration is prevented by coupled cooling, not by singular techniques |
[42]/ 2016 | Num., Cycling/cooling | Prismatic, unknown capacity/ Module | Indirect cooling by aluminum mini-channel tubes coupled into PCM layer between cells | Coupled cooling lowers maximum temperatures; decreasing temperatures with rising thermal conductivity of the PCM |
Parameter | Value |
---|---|
Voltage limits (V) | 3–4.2 |
Nominal capacity (Ah) | 12.5 |
Weight (g) | 260 ± 15 |
Energy density (Wh/kg) | 173 |
Max. charge/discharge current | 1 C |
Operating temperatures (°C) | 0~50 |
Width/Length/Thickness (mm) | 88/192/7.6 |
) @ 1 kHz and 50% SOC | 3.5 |
Cycle stability (-) | 2000 |
Device | Model | Comment | |||
---|---|---|---|---|---|
Power Supply | Delta Elektronika SM15–200 D | Range: 0–15 V, 0–200 A | |||
Refrigeration thermostat | Huber Ministat 240 | Range: −45–200 °C; Cooling power 550 W @ 0 °C | |||
High-speed camera | Photron Fastcam Mini UX100 | 1.280 × 1024 pixels, 250 fps frame rate | |||
Sensors | Model | Range | Max. uncertainty | ||
Temperature | Sheath TC Type K, 1 m × 1 mm | Up to 1300 °C short-term | After calibration: ±0.2 K | ||
Mass flow | Krohne Optimass 6400 C | 0–450 kg/h | ±0.05% of the value | ||
Pressure | Yokogawa EJX110A | 5–1000 mbar | ±0.04% of the value | ||
Voltage | Voltcraft VC 950 Datalogger | 0.001 mV–1000 V | ±0.03% of the value | ||
Data acquisition system | |||||
Rack: NI cDAQ-9174; Modules: NI-9203 Current Input, NI-9213 Thermocouple |
Test Scenario | Experiment Number | Fluid Inlet Temperature (°C) | Comment |
---|---|---|---|
Overcharging, no thermal conditioning | #1–9 | - | Base reference |
Overcharging, thermal conditioning with MCHS | #1*–4* | 5, 20, 30 | Regular cooling |
Overcharging, malfunctioning thermal conditioning with MCHS at critical conditions | #5*c | 40 | Interruption of overcharging |
#6*c | 40 | Interruption of conditioning |
Exp. #1–9 | Non-Linear Increase of Voltage/ Begin Stage II | Voltage Drop/ Begin Stage IV | TR/ Begin Stage V | Duration from Voltage Increase to Drop/ Stages II + III | Duration from Voltage Drop to TR/ Stage IV | |||||||
---|---|---|---|---|---|---|---|---|---|---|---|---|
(V) | Time (min) | SOC (%) | Upper (V) | Lower (V) | Diff. (V) | Time (min) | SOC (%) | Time (min) | SOC (%) | Time (min) | Time (min) | |
Mean | 4.87 | 27.0 | 145 | 6.94 | 5.87 | 1.07 | 43.2 | 172 | 47.7 | 179 | 16.2 | 4.5 |
Std. Dev. | 0.06 | 2.0 | 3 | 0.89 | 0.50 | 0.55 | 2.2 | 4 | 4.4 | 7 | 2.3 | 3.6 |
Exp. | Fluid Inlet Temp. | Starting Temp. of Cell | Non-Linear Increase of Voltage/ Begin Stage II | Voltage Drop/ Begin Stage IV | Duration from Voltage Increase to Drop/ Stage II + III | Max. Temp. OC Cell | ||||||
---|---|---|---|---|---|---|---|---|---|---|---|---|
(°C) | (°C) | (V) | Time (min) | SOC (%) | Upper (V) | Lower (V) | Diff. (V) | Time (min) | SOC (%) | Time (min) | (°C) | |
#1* | 5 | 9 | 4.91 | 23.7 | 139 | 5.83 | 5.30 | 0.53 | 42.9 | 172 | 19.2 | 59 |
#2* | 5 | 6 | 4.75 | 22.7 | 138 | 5.79 | 5.45 | 0.34 | 43.7 | 173 | 20.9 | 55 |
#3* | 20 | 17 | 4.76 | 28.6 | 148 | 5.52 | 5.05 | 0.47 | 43.0 | 172 | 14.5 | 47 |
#4* | 30 | 25 | 4.73 | 28.2 | 148 | 5.67 | 4.82 | 0.85 | 42.8 | 171 | 14.7 | 48 |
Exp. | Fluid Inlet Temp. | Starting Temp. of Cell | Non-Linear Increase of Voltage/ Begin Stage II | Voltage Drop/ Begin Stage IV | Duration from Voltage Increase to Drop/ Stage II + III | Max. Temp. OC Cell | ||||||
---|---|---|---|---|---|---|---|---|---|---|---|---|
(°C) | (°C) | (V) | Time (min) | SOC (%) | Upper (V) | Lower (V) | Diff. (V) | Time (min) | SOC (%) | Time (min) | (°C) | |
#5*c | 40 | 33 | 4.77 | 28.6 | 148 | 5.69 | 4.87 | 0.82 | 39.2 | 165 | 10.6 | 62 |
#6*c | 40 | 34 | 5.01 | 33.9 | 156 | 5.99 | 5.02 | 0.97 | 44.0 | 173 | 10.1 | 59 |
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Graichen, H.-C.; Boye, G.; Sauerhering, J.; Köhler, F.; Beyrau, F. The Impact of a Combined Battery Thermal Management and Safety System Utilizing Polymer Mini-Channel Cold Plates on the Thermal Runaway and Its Propagation. Batteries 2024, 10, 1. https://doi.org/10.3390/batteries10010001
Graichen H-C, Boye G, Sauerhering J, Köhler F, Beyrau F. The Impact of a Combined Battery Thermal Management and Safety System Utilizing Polymer Mini-Channel Cold Plates on the Thermal Runaway and Its Propagation. Batteries. 2024; 10(1):1. https://doi.org/10.3390/batteries10010001
Chicago/Turabian StyleGraichen, Henrik-Christian, Gunar Boye, Jörg Sauerhering, Florian Köhler, and Frank Beyrau. 2024. "The Impact of a Combined Battery Thermal Management and Safety System Utilizing Polymer Mini-Channel Cold Plates on the Thermal Runaway and Its Propagation" Batteries 10, no. 1: 1. https://doi.org/10.3390/batteries10010001