An adaptive thermal management prismatic sodium-ion battery module based on partial immersion liquid cooling

Abstract

This invention discloses an adaptive thermal management prismatic sodium-ion battery module based on partial immersion liquid cooling, comprising a module housing, prismatic battery cells, a multi-parameter sensor array, an intelligent control unit, a graded immersion-cooled collaborative cooling system, and an adaptive structural adjustment module. The multi-parameter sensor array is responsible for collecting key parameters, including battery surface and terminal temperature, operating current, module vibration, internal humidity, and smoke concentration. The intelligent control unit performs data fusion analysis and, based on a dynamically adjusted threshold model, makes decisions and triggers corresponding actions. The graded immersion-cooled collaborative cooling system includes forced air cooling units located on both sides of the module housing and several immersion cooling tanks integrated into the battery mounting bracket. The intelligent control unit activates the graded immersion-cooled collaborative cooling system according to the thermal risk level. This invention achieves efficient, precise, and economical thermal management and safety protection.

Description

Technical Field

[0001] This invention relates to the field of electrochemical energy storage technology, and in particular to an adaptive thermal management prismatic sodium-ion battery module based on partial immersion liquid cooling. Background Technology

[0002] Sodium-ion batteries, due to their abundant resources and low cost, show great promise in large-scale energy storage. However, they still face thermal management challenges and the risk of thermal runaway in high-power, high-energy-density applications. Among existing battery module cooling methods, air cooling has limited efficiency, while liquid cooling plates (cold plates) are insufficient in suppressing internal thermal diffusion and have slow response times. Traditional fully immersion liquid cooling, although highly efficient, suffers from drawbacks such as large size, difficult maintenance, high cost, and extremely high requirements for the sealing of the entire module, making it difficult to popularize in cost- and space-sensitive scenarios such as commercial and industrial energy storage. Furthermore, existing thermal safety systems mostly use single-parameter triggering with fixed thresholds, resulting in insufficient linkage between subsystems (such as cooling, BMS, and fire suppression) and an inability to adaptively and collaboratively protect based on the battery's actual condition (such as aging level) and environmental parameters (such as vibration). Therefore, there is an urgent need for a battery module thermal management solution that combines efficient heat dissipation, rapid response, cost control, and intelligent multi-system collaboration. Summary of the Invention

[0003] To address the above shortcomings, the present invention aims to overcome the deficiencies of the prior art and provide a square-shell sodium-ion battery module based on partial immersion liquid cooling technology. This module achieves efficient, precise, and economical thermal management and safety protection through integrated structural design and multi-parameter adaptive control strategy.

[0004] To achieve the above objectives, the present invention adopts the following technical solution: An adaptive thermal management prismatic sodium-ion battery module based on partial immersion liquid cooling includes a module housing, prismatic battery cells, a multi-parameter sensor array, an intelligent control unit, a graded immersion-type collaborative cooling system, and an adaptive structural adjustment module. The multi-parameter sensor array is responsible for collecting key parameters, including battery surface and terminal temperature, operating current, module vibration, humidity inside the housing, and smoke concentration. The intelligent control unit performs data fusion analysis and, based on a dynamically adjusted threshold model, makes decisions and triggers corresponding actions. The square-shell battery unit is composed of multiple square-shell sodium-ion battery cells arranged in a regular manner and fixed in an integrated battery mounting frame; the battery mounting frame is provided inside the module compartment; the mounting frame integrates multiple independent immersion cooling tanks, each tank corresponding to a row or a battery cell, and the bottom of the tank is provided with a liquid inlet, a liquid outlet and a micro liquid pump. The graded immersion-type collaborative cooling system includes forced air cooling units located on both sides of the module housing, and several immersion cooling tanks integrated into the battery mounting bracket. Each immersion cooling tank is equipped with an independent liquid level adjustment mechanism. The intelligent control unit controls the start and stop of the forced air cooling units and the liquid level of the immersion cooling tanks in stages based on the data from the multi-parameter sensor array. The intelligent control unit activates the graded immersion-type collaborative cooling system in stages according to the thermal risk level.

[0005] Furthermore, the thermal risk level classification is specifically as follows: (1) Primary cooling: When the temperature rise exceeds the temperature rise threshold or the temperature is running at the uniform temperature, the variable speed fan and air duct distributed on both sides of the module are activated to force convection heat dissipation on the battery surface and the outer wall of the immersion cooling tank.

[0006] (2) Secondary cooling: When a local temperature exceeds the standard or the temperature difference is too large, the partition immersion cooling is started. Specifically, the micro pump in the immersion cooling tank of the target area is controlled to raise the liquid level of the insulating coolant and partially immerse the designated lower area of ​​the corresponding square battery, so as to carry out efficient heat conduction through direct liquid contact. (3) Three-stage cooling: When a thermal runaway precursor is detected, including the temperature exceeding the preset temperature runaway threshold and the smoke concentration rising to the preset concentration threshold, the liquid level of all the submerged cooling tanks is raised to the highest level to achieve maximum area cooling of the battery; the explosion-proof high-speed exhaust fan located on the top of the module is started simultaneously to quickly discharge any aerosols or high-temperature gases that may be generated, and is linked with the fire protection system.

[0007] Furthermore, it also includes a BMS linkage interface, which enables the intelligent control unit to interact deeply with the battery management system. When starting the secondary and tertiary cooling stages, it actively requests the BMS connected to the BMS linkage interface to limit the current or pause charging. The intelligent control unit dynamically lowers the trigger temperature threshold of each cooling stage based on the battery's cycle health.

[0008] Furthermore, it also includes a security linkage module, which, during the three-level cooling start-up, simultaneously performs electrical isolation, initiates the preparatory work for the total flooding fire gas release in the start-up chamber, and uploads full-parameter alarm information through the communication module.

[0009] Furthermore, the immersion cooling tank is a rectangular tank with an opening at the top, filled with insulating coolant; the lower part of the square-shell battery cell extends into the immersion cooling tank; the liquid level adjustment mechanism includes a micro pump, a liquid level sensor, and a control valve connected to the intelligent control unit located at the bottom of the tank, used to adjust the liquid level between 0% and 80% of the module chamber height.

[0010] Furthermore, the immersion cooling tank is provided with baffles.

[0011] Furthermore, the multi-parameter sensor array includes a temperature sensor attached to the large surface of the square battery cell, a vibration sensor mounted on the battery mounting bracket, and a smoke sensor located at the top of the module compartment.

[0012] Furthermore, the intelligent control unit incorporates a trigger threshold algorithm based on dynamic adjustment of battery health status; the trigger threshold algorithm specifically involves: establishing a negative correlation mapping relationship between battery health status SOH and cooling trigger temperature thresholds at each level based on battery health status SOH data provided by the battery management system; when battery health status SOH decays, the corresponding temperature trigger thresholds at each level are reduced.

[0013] Furthermore, the adaptive structure adjustment module includes a flexible thermally conductive clip and a driving mechanism mounted on the battery mounting bracket. The driving mechanism is used to drive the piezoelectric ceramic or micro motor of the flexible thermally conductive clip to make micro-movements. When the vibration parameters exceed the standard, the intelligent control unit controls the driving mechanism to adjust the lateral pressure of the clip on the battery to maintain stable thermomechanical contact.

[0014] Compared with the prior art, the beneficial effects of the present invention are as follows: (1) Efficient and economical immersion cooling: The design of “partial immersion” and “zone controllable” significantly reduces the amount of coolant and tank size compared with the full immersion scheme, reducing costs and weight, while retaining the core advantage of high heat transfer coefficient of immersion liquid cooling, which can quickly suppress hot spots and heat spread.

[0015] (2) Optimized design for prismatic batteries: The integrated mounting bracket and cooling tank structure make full use of the regular plane of the prismatic battery, so that the contact area between the coolant and the battery wall is large and uniform, and the thermal resistance is small. The adjustable immersion depth design allows the cooling intensity to be precisely matched with the thermal runaway development stage.

[0016] (3) Intelligent collaboration and self-adaptation: Through multi-parameter perception and dynamic threshold model, the rigid mode of traditional single temperature point triggering has been changed, realizing the forward-looking linkage and adaptive adjustment of cooling system, BMS, structural safety and fire protection system, and constructing a defense-in-depth system.

[0017] (4) The immersion cooling tank itself can serve as a secondary enclosure for the battery module. Even if the battery leaks, the coolant can play a certain role in blocking and diluting the leakage. Combined with emergency ventilation, this improves the overall safety of the module.

[0018] (5) The immersion coolant storage tank is located outside the immersion cooling tank and connected to multiple immersion cooling tanks. When a problem occurs in a single battery module, it is handled in different areas to reduce losses. Attached Figure Description

[0019] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below.

[0020] Figure 1 This is a system principle block diagram of a partially immersed liquid-cooled adaptive thermal management square-shell sodium-ion battery module according to an embodiment of the present invention.

[0021] Figure 2 This is a schematic diagram of the primary cooling stage of a square-shell sodium-ion battery module based on partially immersed liquid cooling, according to an embodiment of the present invention.

[0022] Figure 3 This is a schematic diagram of a two-stage cooling system for a square-shell sodium-ion battery module based on partially immersion liquid cooling, according to an embodiment of the present invention.

[0023] Figure 4 This is a schematic diagram of a three-stage cooling system for a square-shell sodium-ion battery module based on partially immersion liquid cooling, according to an embodiment of the present invention. Detailed Implementation

[0024] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0025] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0026] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances. Furthermore, the technical features involved in the different embodiments of this invention described below can be combined with each other as long as they do not conflict with each other.

[0027] like Figure 1 As shown, an adaptive thermal management prismatic sodium-ion battery module based on partial immersion liquid cooling includes a module housing, prismatic battery cells, a multi-parameter sensor array, an intelligent control unit, a graded immersion-type collaborative cooling system, an adaptive structural adjustment module, a BMS linkage interface, and a security linkage module. The multi-parameter sensor array is responsible for collecting key parameters, including battery surface and terminal temperature, operating current, module vibration, internal humidity, and smoke concentration. The intelligent control unit performs data fusion analysis and, based on a dynamically adjusted threshold model, makes decisions and triggers corresponding actions.

[0028] The prismatic battery unit is composed of multiple prismatic sodium-ion battery cells arranged in a regular pattern and fixed in an integrated battery mounting frame; the battery mounting frame is located inside the module compartment. The mounting frame integrates multiple independent immersion cooling tanks, each corresponding to a row or a single battery cell, and the bottom of the tank is equipped with a liquid inlet, a liquid outlet, and a micro liquid pump.

[0029] The BMS linkage interface enables the intelligent control unit to interact deeply with the battery management system. When starting the secondary and tertiary cooling stages, it actively requests the BMS connected to the BMS linkage interface to limit current or pause charging. The intelligent control unit dynamically lowers the trigger temperature threshold of each cooling stage based on the battery's cycle health.

[0030] When the security linkage module starts with the third-level cooling, it simultaneously performs electrical isolation, initiates the preparation for the total flooding fire-fighting gas release in the start-up chamber, and uploads full-parameter alarm information through the communication module.

[0031] The graded immersion co-cooling system includes forced air cooling units located on both sides of the module housing, and several immersion cooling tanks integrated into the battery mounting bracket. Each immersion cooling tank is equipped with an independent liquid level adjustment mechanism. The intelligent control unit, based on data from the multi-parameter sensor array, gradedly controls the start / stop of the forced air cooling units and the liquid level in the immersion cooling tanks. The intelligent control unit activates the graded immersion co-cooling system according to the thermal risk level. The thermal risk level classification is as follows: (1) Primary cooling: When the temperature rise exceeds the temperature rise threshold or the temperature is running at a constant level, the variable speed fans and air ducts distributed on both sides of the module are activated to force convection heat dissipation on the battery surface and the outer wall of the immersion cooling tank, such as... Figure 2 As shown.

[0032] (2) Secondary cooling: When a local temperature exceeds the standard or the temperature difference is too large, zoned immersion cooling is activated. Specifically, the micro-pump in the immersion cooling tank of the target area is controlled to raise the level of the insulating coolant, partially immersing the designated lower area of ​​the corresponding square-shell battery, achieving efficient heat conduction through direct liquid contact; such as Figure 3 As shown.

[0033] (3) Three-stage cooling: When signs of impending thermal runaway are detected, including temperatures exceeding a preset temperature runaway threshold and smoke concentration rising to a preset concentration threshold, the liquid levels in all submerged cooling tanks are raised to the highest level to achieve maximum area cooling of the battery. Simultaneously, the explosion-proof high-speed exhaust fan located on top of the module is activated to quickly exhaust any aerosols or high-temperature gases that may be generated, and is linked to the fire suppression system. Figure 4 As shown.

[0034] The immersion cooling tank is a rectangular tank with an opening at the top, filled with insulating coolant. The lower part of the prismatic battery cell extends into the immersion cooling tank. The liquid level adjustment mechanism includes a micro pump located at the bottom of the tank, a liquid level sensor, and a control valve connected to an intelligent control unit, used to adjust the liquid level between 0% and 80% of the module chamber height.

[0035] The immersion cooling tank is equipped with baffles.

[0036] The multi-parameter sensor array includes a temperature sensor attached to the large surface of the square battery cell, a vibration sensor mounted on the battery mounting bracket, and a smoke sensor located at the top of the module compartment.

[0037] The intelligent control unit incorporates a trigger threshold algorithm that dynamically adjusts based on battery health status. The basic principle of this algorithm is as follows: based on the battery health status (SOH) data provided by the battery management system (BMS), a negative correlation mapping relationship is established between SOH and the cooling trigger temperature thresholds at each level; when SOH decays, the corresponding temperature trigger thresholds at each level are lowered, thereby enabling the cooling strategy to adaptively advance and enhance with the degree of battery aging.

[0038] The adaptive structural adjustment module includes a flexible thermally conductive clip and a drive mechanism mounted on the battery mounting bracket. The drive mechanism is used to drive the piezoelectric ceramic or micro motor that makes the flexible thermally conductive clip move slightly. When the vibration parameters exceed the standard, the intelligent control unit controls the drive mechanism to adjust the lateral pressure of the clip on the battery in order to maintain stable thermomechanical contact.

[0039] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A prismatic sodium-ion battery module with adaptive thermal management based on partial immersion liquid cooling, characterized in that, It includes a module housing, a square-shell battery unit, a multi-parameter sensor array, an intelligent control unit, a graded immersion-type collaborative cooling system, and an adaptive structural adjustment module; the multi-parameter sensor array is responsible for collecting key parameters; the key parameters include battery surface and terminal temperature, operating current, module vibration, cabin humidity, and smoke concentration; the intelligent control unit performs data fusion analysis, and makes decisions and triggers corresponding actions based on a dynamically adjusted threshold model; The square-shell battery unit is composed of multiple square-shell sodium-ion battery cells arranged in a regular manner and fixed in an integrated battery mounting frame; the battery mounting frame is provided inside the module compartment; The mounting frame integrates multiple independent immersion cooling tanks, each corresponding to a row or a single battery cell. The bottom of the tank is equipped with a liquid inlet, a liquid outlet, and a micro liquid pump. The graded immersion-type collaborative cooling system includes forced air cooling units located on both sides of the module housing, and several immersion cooling tanks integrated into the battery mounting bracket. Each immersion cooling tank is equipped with an independent liquid level adjustment mechanism. The intelligent control unit controls the start and stop of the forced air cooling units and the liquid level of the immersion cooling tanks in stages based on the data from the multi-parameter sensor array. The intelligent control unit activates the graded immersion-type collaborative cooling system in stages according to the thermal risk level.

2. The adaptive thermal management square-shell sodium-ion battery module based on partial immersion liquid cooling according to claim 1, characterized in that: The specific classification of thermal risk levels is as follows: (1) Primary cooling: When the temperature rise exceeds the temperature rise threshold or the temperature is running at the uniform temperature, the variable speed fan and air duct distributed on both sides of the module are activated to force convection heat dissipation on the battery surface and the outer wall of the immersion cooling tank. (2) Secondary cooling: When a local temperature exceeds the standard or the temperature difference is too large, the partition immersion cooling is started. Specifically, the micro pump in the immersion cooling tank of the target area is controlled to raise the liquid level of the insulating coolant and partially immerse the designated lower area of ​​the corresponding square battery, so as to carry out efficient heat conduction through direct liquid contact. (3) Three-stage cooling: When a thermal runaway precursor is detected, including the temperature exceeding the preset temperature runaway threshold and the smoke concentration rising to the preset concentration threshold, the liquid level of all the submerged cooling tanks is raised to the highest level to achieve maximum area cooling of the battery. The explosion-proof high-speed exhaust fan located on top of the module is activated simultaneously to quickly exhaust any aerosols or high-temperature gases that may be generated, and it is linked with the fire protection system.

3. The adaptive thermal management square-shell sodium-ion battery module based on partial immersion liquid cooling according to claim 1, characterized in that: It also includes a BMS linkage interface, which enables the intelligent control unit to interact deeply with the battery management system. When starting the secondary and tertiary cooling stages, it actively requests the BMS connected to the BMS linkage interface to limit the current or pause charging. The intelligent control unit dynamically lowers the trigger temperature threshold of each cooling stage based on the battery cycle health.

4. A sodium-ion battery module with adaptive thermal management based on partial immersion liquid cooling according to claim 1, characterized in that: It also includes a security linkage module, which, when activated by the three-level cooling system, simultaneously performs electrical isolation, initiates the preparatory work for the total flooding fire-fighting gas release in the cabin, and uploads full-parameter alarm information via the communication module.

5. A sodium-ion battery module with adaptive thermal management based on partial immersion liquid cooling according to claim 1, characterized in that: The immersion cooling tank is a rectangular tank with an opening at the top, filled with insulating coolant; the lower part of the square-shell battery cell extends into the immersion cooling tank; the liquid level adjustment mechanism includes a micro pump, a liquid level sensor, and a control valve connected to the intelligent control unit located at the bottom of the tank, used to adjust the liquid level between 0% and 80% of the module chamber height.

6. A sodium-ion battery module with adaptive thermal management based on partial immersion liquid cooling according to claim 1, characterized in that: The immersion cooling tank is equipped with baffles.

7. A sodium-ion battery module with adaptive thermal management based on partial immersion liquid cooling according to claim 1, characterized in that: The multi-parameter sensor array includes a temperature sensor attached to the large surface of the square battery cell, a vibration sensor mounted on the battery mounting bracket, and a smoke sensor located on the top of the module compartment.

8. A sodium-ion battery module with adaptive thermal management based on partial immersion liquid cooling according to claim 1, characterized in that: The intelligent control unit incorporates a trigger threshold algorithm based on dynamic adjustment of battery health status. Specifically, the trigger threshold algorithm establishes a negative correlation mapping relationship between battery health status (SOH) and cooling trigger temperature thresholds at each level based on the battery health status (SOH) data provided by the battery management system. When the battery health status (SOH) decays, the corresponding temperature trigger thresholds at each level are reduced.

9. A sodium-ion battery module with adaptive thermal management based on partial immersion liquid cooling according to claim 1, characterized in that: The adaptive structure adjustment module includes a flexible thermally conductive clip and a driving mechanism mounted on the battery mounting bracket. The driving mechanism is used to drive the piezoelectric ceramic or micro motor of the flexible thermally conductive clip to make micro-movements. When the vibration parameters exceed the standard, the intelligent control unit controls the driving mechanism to adjust the lateral pressure of the clip on the battery to maintain stable thermomechanical contact.

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