A composite structure global refrigerant coupling fluorinated liquid heat management integrated architecture

Abstract

The application discloses a composite structure global refrigerant coupling fluorinated liquid heat management integrated architecture, and belongs to the technical field of new energy power battery vehicle level heat management. The scheme adopts a multi-layer composite enclosure box body, realizes global immersion heat exchange of the fluorinated liquid of the battery cell by relying on a 360-degree cavity, carries a variable frequency closed loop temperature control system, is suitable for high-power fast charging above 240KW, effectively improves the problems of insufficient heat dissipation, large temperature difference, easy diffusion of thermal runaway and the like of the traditional box body, and simultaneously has the abilities of heat insulation, flame retardation, collision protection and the like.

Description

Technical Field

[0001] This invention belongs to the technical field of full-domain thermal management system for power batteries of new energy vehicles. Unlike existing component structure patents with single battery box and single-sided heat dissipation cover, this invention is a vehicle-level integrated thermal management system architecture, specifically adapted to ultra-high power and ultra-fast charging power battery packs of 240kW~1000kW and above. It integrates a multi-composite protection system of full-domain active heat exchange, full-temperature constant temperature lock, full-domain flame retardant and thermal runaway suppression, and three-dimensional uniform temperature. It solves the industry shortcomings of traditional single-sided heat dissipation battery boxes, which can only bear charging power of up to 240kW, large temperature difference, poor high and low temperature adaptability, and lack of active full-domain refrigerant regulation. Background Technology

[0002] Based on my own cutting-edge technology research and development foundation, I will upgrade and modify the technology to address any shortcomings. The existing first-generation patent (a multi-layer composite power battery box and top cover structure with intelligent solar static constant temperature, patent number: 202610483140.1) is limited to a single-sided heat dissipation hardware structure for the battery box body and top cover, which is a component improvement solution and has insurmountable technical limitations: Single heat exchange dimension: It relies on passive heat dissipation on only the bottom and top cover of the box, without a surrounding three-dimensional refrigerant flow channel coupled heat exchange structure. The heat exchange area is limited, and the maximum heat dissipation capacity is only suitable for conventional charging power of 240kW and below. Under ultra-high power fast charging conditions, the battery cells have local heat accumulation and excessive temperature difference, which cannot be adapted to the new generation of 800V high voltage platform and 1000A-level ultra-fast charging models. Passive temperature control logic: The first-generation solution relies on static passive heat dissipation of fluorinated liquid and weak constant temperature with solar assistance. It lacks an independent closed-loop refrigerant active circulation temperature control architecture, and cannot dynamically and accurately adjust the temperature of the fluorinated liquid medium. It can only maintain a wide temperature range and cannot stably lock the cell in the golden operating range of 25~35℃. There is no active temperature locking compensation in low-temperature environments and no all-area rapid heat dissipation mechanism in high-temperature environments. The insulation interlayer has defects: the first generation only uses a whole piece of unsupported aerogel to fill the interlayer without a three-dimensional pressure-bearing support frame. Under the bumpy and squeezed conditions of the battery box on the vehicle, the aerogel is easily compacted and collapsed, the insulation gap disappears, and the heat lock-in and insulation performance is greatly reduced. Structural limitations: The first-generation protection system consists of the battery box shell and the top cover sealing structure, which can only achieve box sealing and basic heat insulation. It has not built an integrated system architecture of "enclosure heat insulation layer + full-area refrigerant heat exchange layer + immersion medium + vehicle temperature control algorithm". It can only be supplied as a component and cannot form a vehicle thermal management platform-level solution for car manufacturers. There are shortcomings in thermal runaway protection: single-sided heat dissipation can only dissipate local heat, and there is no synchronous heat exchange structure on the side and bottom of the cell. When a single cell has a thermal anomaly, the heat spreads rapidly laterally, and it is impossible to block the thermal chain reaction from a 360° all-dimensional perspective. Summary of the Invention

[0003] Other immersion battery thermal management solutions on the market either only add bottom water cooling or simply thicken the insulation layer of the enclosure. They have not broken away from the R&D idea of ​​"improving the battery enclosure hardware". They do not have a three-dimensional surrounding refrigerant coupling heat exchange system that covers the entire outer periphery of the battery cell, and they lack system-level vehicle thermal flow control logic. The industry urgently needs a full-domain thermal management solution that is independent of a single enclosure structure and has a completely new architecture level.

[0004] Addressing the shortcomings of first-generation single-sided heat dissipation battery boxes and existing industry technologies, this invention provides a composite structure with a fully integrated refrigerant-coupled fluorinated liquid thermal management architecture. Instead of focusing on improvements to individual components such as the battery box or top cover, this invention constructs a complete vehicle-level thermal management platform. It utilizes a 360° (meaning six-dimensional heat exchange coverage, including the four side walls, bottom, and top cover) three-dimensional refrigerant flow channel as the core heat exchange carrier, coupled with a PEEK equilateral triangular grid integrated pyramid matrix cylindrical support frame composite insulation layer, static fluorinated liquid full-area immersion, and closed-loop dynamic temperature control logic. This enables stable operation of continuous ultra-fast charging at 240~1000kW and above, precisely controlling the cell constant temperature range of 25~35℃, and expanding the safe operating temperature range to 17~49℃. It fundamentally solves four major industry pain points from the architecture: heat accumulation during ultra-high power fast charging, low-temperature range degradation, thermal runaway cascading propagation, and easy collapse of the insulation interlayer. The core innovation of the overall architecture (a key difference completely distinguishing it from the first-generation patent) The innovations of the first-generation patent focused on: a multi-layer composite outer shell, single-sided heat dissipation on the top cover, solar-assisted static temperature control, a supportless, single-piece aerogel interlayer, and a sealed, flame-retardant structure for the enclosure. This invention innovates on a system integration architecture, with five independent core modules that were completely undisclosed and undocumented in the first generation. Module 1: Aluminum-carbon-aluminum integrated 360° surround hollow refrigerant flow channel heat exchange module (heat exchange is fully covered around the battery cell, bottom and top cover, first generation without built-in refrigerant circulation). Module 2: PEEK equilateral triangular grid pyramid lattice cylindrical composite thermal insulation enclosure module (integrated triangular grid + node three-dimensional cylindrical support, solving the collapse defect of first-generation aerogel, which is the unique sandwich structure of this invention). Module 3: Refrigerant circulation system and static fluorinated liquid indirect coupling heat exchange system (new heat exchange mechanism, prior patent has no active refrigerant loop). Module 4: 25 / 35℃ dual threshold frequency conversion closed-loop layered temperature control system (first generation only has solar passive constant temperature, no electronic active adjustment); Module 5: Ultra-thin horizontal heat-conducting sheet between compartments for full-area cross-compartment temperature equalization structure (aiding in reducing the temperature difference of the entire battery pack cells, a first-generation design without cross-compartment temperature equalization).

[0005] Specific structure and implementation details 1. Multi-layer composite enclosure outer structure (including newly added triangular grid pyramid matrix cylindrical support frame): The enclosure consists of an outer aluminum alloy protective layer, an aerogel insulation interlayer, and an aluminum-carbon-aluminum composite inner layer plate, arranged sequentially from the outside to the inside. The outer aluminum alloy protective layer is made of 6061 aluminum with a sidewall thickness of 1.2mm, and the outer aluminum alloy at the bottom of the cavity is thickened to 1.5mm. The aerogel insulation interlayer has a fixed thickness of 5mm, and an integrally injection-molded PEEK equilateral triangular grid pyramid matrix cylindrical support frame is embedded inside the interlayer. The PEEK equilateral triangular grid pyramid lattice cylindrical support frame consists of multiple PEEK ribs arranged in a crisscross pattern, with each pair of ribs intersecting to form a uniform equilateral triangular hollow grid. All rib intersections are integrally injection molded upwards to form a three-dimensional pyramid cylindrical support unit. The two ends of the pyramid lattice cylindrical unit are respectively pressed against the inner wall of the outer aluminum alloy protective layer and the outer wall of the inner aluminum-carbon-aluminum composite plate, completely suspending the two layers of plates and forming a stable heat-insulating cavity inside the interlayer. Aerogel is uniformly filled in all hollow areas of the triangular grid. The triangular grid structure relies on the inherent mechanical self-stabilizing properties of equilateral triangles, and with the same amount of material, its compressive and vibration resistance is superior to that of a rhomboid grid. The support points are evenly distributed throughout the entire area, and the aerogel will not be compacted under long-term vehicle bumps and box compression conditions, ensuring that the heat insulation performance of the interlayer remains unchanged throughout the process. The aluminum-carbon-aluminum composite inner layer plate has a layered structure consisting of a 0.6mm outer aluminum layer, a 1.2mm carbon fiber substrate, and a 2mm inner aluminum layer. The inner layer plate features an integrated, horizontally perforated hollow refrigerant channel. Multiple inner layers are joined to form a 360° three-dimensional heat exchange cavity that completely encloses the battery cell. All the hollow refrigerant channels are interconnected, forming a full-area refrigerant circulation loop. The bottom of the cavity features an integrally stamped longitudinal rib and a transverse protective buffer, enhancing its impact resistance. This is a key distinguishing feature of this invention, as it lacks a built-in refrigerant channel structure and relies solely on passive heat dissipation from the outer shell. The battery compartment is equipped with a GF-PEEK glass fiber reinforced PEEK hollow insulation bracket. The bracket has a hollow mesh structure that supports the entire power battery in the air. The GF-PEEK material has high insulation and low thermal conductivity, which isolates the metal outer wall of the battery cell from direct contact with the aluminum-carbon-aluminum composite plate, eliminating the risk of conductive short circuit. The hollow channels of the bracket allow the fluorinated liquid in the sealed cavity to flow freely through. The fluorinated liquid completely surrounds the outer periphery of the battery cell, ensuring full immersion heat exchange effect and preventing local heat accumulation caused by the solid plate blocking the fluid.

[0006] 2. Full-area refrigerant coupling heat exchange system (a completely new core, with no corresponding structure in the first generation): The hollow flow channels of the inner aluminum-carbon aluminum plate form a complete refrigerant circulation loop, with three flow layouts: single-pipe, dual-pipe, and four-pipe. It is connected to an external variable frequency compressor for refrigeration circulation. The environmentally friendly new refrigerant flows inside the flow channels. The refrigerant and the fluorinated liquid in the box exchange heat indirectly only through the 6061 aluminum wall, and the two are completely isolated and do not come into contact. It is equipped with a thermocouple temperature acquisition component, which sets the trigger refrigeration threshold of 35℃ and the stop refrigeration threshold of 25℃, and adjusts the refrigerant circulation flow in real time in a closed loop. An ultra-thin heat-conducting plate is added between the left and right battery compartment walls of the box to accelerate the lateral temperature uniformity of the fluorinated liquid and further reduce the temperature difference of the entire battery pack. This heat-conducting coupling structure is an additional temperature uniformity design that was not mentioned in the first generation.

[0007] 3. Static Fluoride Immersion Temperature-Controlled System (Upgraded Mechanism): The battery compartment is filled with a perfluorofluoride medium, and the volume ratio of the fluoride to the power battery cell is fixed at 1:2.05. The enclosure is completely sealed and statically stores the fluoride. Relying on the continuous heat exchange through the internal full-area refrigerant flow channel, the fluoride is maintained stably within the safe range of 17~49℃ for a long time, eliminating the problem of expansion, contraction and deformation of the medium at high and low temperatures. Compared with the first generation, which only relied on the top cover for heat dissipation and contact with the fluoride, the sides, bottom and top of the battery cell in this invention are all immersed in the temperature-controlled fluoride, and the outer periphery is simultaneously wrapped by the refrigerant flow channel, improving the heat exchange efficiency by more than 500% and enabling continuous fast charging of ultra-high power of more than 1000kW.

[0008] 4. The multi-layer composite enclosure of the cross-compartment temperature equalization auxiliary structure is divided into at least two independent battery compartments. Ultra-thin heat-conducting sheets are installed between the walls of the two adjacent battery compartments. The ultra-thin heat-conducting sheets are attached to the fluorinated liquid in the compartments on both sides, so as to realize heat exchange between multiple compartments and synchronous temperature equalization throughout the entire area, further reducing the temperature difference of the entire battery pack.

[0009] 5. Vehicle-wide Layered Closed-Loop Temperature Control Logic Architecture (System-level Innovation, First Generation Algorithm-Free System) The closed-loop variable frequency temperature control module includes thermocouple temperature sensors arranged in the cavity. The thermocouples are connected to the signal terminals of the variable frequency compressor's electronic control unit. It sets a cooling start threshold of 35℃ and a cooling stop threshold of 25℃, automatically adjusts the refrigerant circulation flow rate based on the real-time temperature of the fluorinated liquid, and distinguishes three independent operating logic levels: Low temperature operation: When the inverter compressor stops, the aerogel jacket + PEEK triangular grid pyramid support frame jointly lock in the residual heat of the battery cell to maintain the temperature of the fluorinated liquid at no less than 17°C and reduce the reduction of winter range. Under normal fast charging conditions (within 240kW): the inverter compressor operates at low power and low frequency to maintain the fluorinated liquid at the optimal constant temperature range of 25℃~35℃ for the battery cell; Ultra-fast charging mode (240kW~1000kW and above): The inverter compressor operates at full load and high speed continuously, and the refrigerant circulates and heats in 360° synchronously throughout the entire area, quickly removing the heat that accumulates instantly in the battery cell and eliminating local high temperature hotspots; Thermal anomaly extreme conditions: The entire refrigerant circulation loop operates at full load, and the 360° three-dimensional heat exchange cavity synchronously blocks the lateral heat conduction. Combined with the flame-retardant and rapid heat absorption characteristics of the fluorinated liquid, it prevents the entire package from thermally cascading out of control caused by a single cell failure, and ensures that no fire occurs under impact or short circuit conditions.

[0010] For low-temperature winter use, solar energy or battery packs, auxiliary batteries, intelligent temperature control modules, and low-power heating plates can be used to raise the overall temperature of the fluorinated liquid to 25°C when the temperature drops below 10°C, ensuring that the internal temperature does not fall below 10°C. The intelligent temperature control module can automatically switch power supply modes. When there is sufficient sunlight, the solar power supply components directly power the system to drive the circulation. When there is no sunlight / it is cloudy / at night, it automatically switches to auxiliary battery power supply. In an external environment of -40°C to 60°C, the internal battery area temperature can be precisely kept constant at 10-25°C. Combined with the fluorinated liquid fully immersed heat dissipation structure, the heating and heat dissipation response speed is doubled, reducing energy consumption while improving the battery's environmental adaptability and service life. Beneficial effects

[0011] 1. The technology levels are completely separate, with no risk of patent overlap. The first generation was an improvement on the structure of battery box and top cover components, and the protection scope only covered the outer shell of the box, a single-sided heat dissipation top cover, and an unsupported aerogel interlayer. This invention is an integrated architecture for the whole vehicle thermal management system, with core protection of a full-domain three-dimensional refrigerant flow channel coupled heat exchange system, a PEEK equilateral triangular grid pyramid dot matrix cylindrical support interlayer, and a closed-loop active temperature control system. The innovation points, protected objects, and technical mechanisms are completely different, with no conflict or overlap, forming a high-low combination of patent barriers, which competitors cannot bypass by using the two sets of patents.

[0012] 2. The power carrying capacity has been greatly improved, breaking through the first generation's power limit of 240kW, and stably supporting 240~1000kW and above ultra-fast charging. The full-area three-dimensional heat exchange greatly reduces the temperature difference of the battery cells, solving the pain points of high voltage fast charging heat generation and rapid battery degradation. 3. Full-temperature-range bidirectional optimization: Low temperature relies on composite enclosure for heat locking and low-power heating components, significantly reducing winter power loss; High temperature relies on 360° refrigerant rapid heat exchange, accurately controlling the constant temperature range of the medium, and adapting to all seasons. 4. Full-temperature-range bidirectional optimization: Low temperature relies on the long-term heat lock of the composite enclosure layer, which greatly reduces the loss of winter endurance; high temperature relies on 360° refrigerant rapid heat exchange, which accurately controls the constant temperature range of the medium, and can be stably adapted to high and low temperature conditions in all seasons. 5. Full-area layered safety protection: All outer peripheries of the battery cell are simultaneously cooled; the entire area is immersed in fluorinated liquid for flame retardancy; the triangular mesh support buffers the impact force; and it can quickly suppress heat under short circuit, puncture, and impact conditions, completely avoiding thermal chain runaway fire. 6. Enhanced Commercial Value: The first-generation patent could only license and sell battery box components; this invention provides a complete thermal management platform architecture that OEMs can directly purchase, with the entire solution delivered as a package. The technology premium and licensing value are significantly higher than the first-generation box patent.

[0013] Detailed Implementation Examples Step 1: Outer composite shell integral molding The outer enclosure shell is made of 6061 aluminum alloy through die casting. Longitudinal ribs and transverse buffer ribs are simultaneously formed at the bottom of the shell to improve the overall vehicle's collision protection performance. The middle carbon fiber interlayer is integrally molded during the die casting process, forming the outer enclosure composite frame. Step 2: Integral injection molding of PEEK equilateral triangular grid pyramid dot matrix cylindrical support skeleton, with ribs intersecting to form equilateral triangular hollow grid, and the intersecting nodes integrally molded pyramid dot matrix cylindrical support column. The cylinder height is 5mm, the diameter is 3mm, the rib width is 2mm, and the height is 2mm. Step 3: Fill the interior of the PEEK triangular grid pyramid lattice skeleton with 5mm aerogel to form a complete composite thermal insulation interlayer. Step 4: Independent processing of aluminum-carbon aluminum inner heat exchange plates A separate 6061 aluminum plate is cut for the inner layer. A transverse hollow refrigerant channel (channel width 0.5-1.5mm, preferably 1mm, adjacent channels spaced 5-30mm, preferably 20mm) is integrally drilled while the plate remains undeformed. Matching male and female connectors are machined at both ends of each channel section to obtain an independent heat exchange inner layer. Aerogel is filled into the PEEK pyramid lattice framework and hot-pressed with the aluminum-carbon-aluminum plate to form a composite insulation sandwich layer. Step 5: Assembly and fluid sealing of the six-sided full-area heat exchange cavity Multiple finished inner heat exchange plates are embedded inside the outer die-cast composite frame. The refrigerant channels of adjacent plates are precisely aligned by end male and female connectors. The joints are sealed with aluminum brazing to connect all refrigerant pipelines, forming a 360° surround heat exchange cavity (including the four side walls, bottom, and top cover of the shell). Bending and limiting ribs are set on the edges of the plates to achieve mechanical pre-positioning.

[0014] Step 6: Multi-layer composite sandwich thermal insulation and sealing treatment The joints between the layers of the multi-layer composite enclosure are filled with high-temperature resistant soft structural adhesive to form a complete sealed cavity. The structural adhesive fills the gaps between different materials such as metal, aerogel, and PEEK, blocking thermal bridges and buffering the thermal expansion and contraction deformation of multiple materials while isolating external moisture and dust.

[0015] Step 7: Refrigeration and Temperature Control Hardware Assembly It connects all the refrigerant channels in the inner layer with the external variable frequency compressor refrigeration unit. Thermocouple temperature sensing components are installed inside the cavity. It has a closed-loop temperature control logic that starts refrigeration at 25°C and stops refrigeration at 35°C. It is connected to the vehicle's BMS thermal management controller to achieve full-domain automated constant temperature control.

[0016] Step 8: Add fluorinated liquid to immerse the battery cell The perfluorinated liquid is added to the sealed battery compartment at a volume ratio of 1:1.6 to 1:2.7 (preferably 1:2.05) to completely immerse the battery cell module in the fluorinated liquid medium. The safe operating temperature range of the fluorinated liquid covers 17℃ to 49℃, which can offset the dimensional fluctuations caused by thermal expansion and deformation of the medium.

[0017] Step 9 (Optional assembly, advanced structure optimization) If the battery compartment is divided into two or more independent compartments, an ultra-thin heat-conducting sheet can be selected between the walls of adjacent battery compartments; the ultra-thin heat-conducting sheet contacts the fluorinated liquid in the compartments on both sides respectively, achieving uniform heat distribution across the entire compartment and reducing the temperature difference of the entire battery pack; this component can be omitted in a single-compartment layout.

[0018] Step 10: Overhead assembly of battery cell insulation A GF-PEEK integrated hollow insulation bracket is installed at the bottom of the battery cell to suspend the entire battery cell, isolate the metal electrode shell of the battery cell from the inner aluminum heat exchange plate, avoid conductive short circuits, and ensure that the fluorinated liquid completely covers the entire surface of the battery cell.

[0019] Step 11: Extended Solution for Auxiliary Heating in Low-Temperature Conditions In low-temperature winter operating conditions, a low-power heating plate can be installed. The heating plate can be powered by any of the following methods: power battery, vehicle integrated power supply, solar power supply, or auxiliary battery power supply. It is used to lock in the temperature at low temperatures and maintain the temperature of the fluorinated liquid at no less than 17°C.

[0020] The above are merely preferred embodiments of the present invention. Any technical solutions based on the core architecture of the present invention, namely "360° refrigerant flow channel coupled with fluorinated liquid heat exchange, multi-layer composite enclosure for temperature locking, and closed-loop layered temperature control of the whole vehicle", involving equivalent replacement of pipeline layout, plate thickness, refrigerant type, insulation material, and simple parameter adjustment, shall fall within the protection scope of the claims of the present invention.

[0021] Explanation of the distinction between the two generations of patents 1. Distinction of protected objects First generation: Power battery box + single-sided heat dissipation component structure, with innovations concentrated in the outer box composite material, single-sided heat dissipation top cover, box sealing and flame retardant, and unsupported whole aerogel sandwich layer; The second generation features a vehicle-level integrated thermal management system architecture. Its core innovations include a 360° surround refrigerant hollow flow channel, active refrigerant circulation coupled heat exchange, a PEEK triangular grid pyramid matrix cylindrical three-dimensional support sandwich layer, and a layered closed-loop temperature control algorithm. The core improvement is not to reduce heat dissipation on one side of the top cover.

[0022] 2. Essential distinction in heat exchange mechanisms First generation: passive heat dissipation, relying solely on the metal casing of the enclosure and top cover to conduct heat from the fluorinated liquid, without an active refrigerant circulation heat exchange structure, and the heat exchange surface is only the top of the battery cell; Second generation: Active full-area coupling heat exchange, the battery cell is completely wrapped in aluminum-carbon aluminum plates with refrigerant flow channels around, bottom and top, the refrigerant circulation actively removes the heat of the fluorinated liquid, and the temperature is uniform in three dimensions.

[0023] 3. Essential distinctions in thermal insulation sandwich structure First generation: Pure aerogel filler without a three-dimensional support framework, prone to collapse after long-term use; Second generation: Aerogel + integrated PEEK triangular grid pyramid lattice cylindrical composite sandwich layer, triangular grid nodes cylinder bearing pressure, thermal insulation gap permanently stable.

[0024] 4. Power Adaptation Level Differentiation The first generation design has a maximum power of 240kW for conventional fast charging and lacks a high-power heat dissipation design. The second-generation heat exchange system is specifically designed for 800~1000kW ultra-high voltage and ultra-fast charging, solving the power bottleneck of the first generation.

[0025] 5. Independent Boundaries of Technical Solutions The second generation does not reuse the core single-sided heat dissipation structure of the first generation. Instead, it adds three independent core modules: a full-domain refrigerant circulation system, a triangular grid pyramid matrix support layer, and a vehicle temperature control logic. Compared with the first generation, it has outstanding substantive features and significant progress. There is no overlap with the technology of the first generation patent, and it has independent novelty and inventiveness. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the layered structure of the shell in Embodiment 1 of the present invention; Figure 2 This is a schematic diagram of the PEEK triangular mesh pyramid lattice skeleton in Embodiment 1 of the present invention; Figure 3 This refers to the GF-PEEK integrated hollow insulating bracket in Embodiment 1 of the present invention; Among them, 1. is the outer aluminum alloy layer of the casing; 2. PEEK triangular mesh pyramid lattice cylindrical skeleton + aerogel hollow layer; 3. is the outer aluminum layer of the aluminum-carbon fiber-aluminum composite structure layer; 4. is the carbon fiber layer of the aluminum-carbon fiber-aluminum composite structure layer; 5. is the inner aluminum layer of the aluminum-carbon fiber-aluminum composite structure layer; 6. is the refrigerant channel of the inner aluminum layer; 7. is the plan view of the PEEK triangular mesh pyramid lattice skeleton; 8. is the oblique view of the PEEK triangular mesh pyramid lattice skeleton; 9. is the GF-PEEK integrated hollow insulation bracket.

Claims

1. A composite structure global refrigerant coupled fluorinated liquid thermal management integrated architecture, characterized in that: Includes a multi-layer composite enclosure shell, a full-area refrigerant coupling heat exchange module, a static fluorinated liquid immersion temperature control system, a closed-loop variable temperature control module, and a hollowed-out insulating support assembly; The multi-layer composite enclosure shell forms a sealed cavity for accommodating the power battery. A full-range refrigerant coupling heat exchange module is installed inside the cavity, and the heat exchange module is arranged omnidirectionally along the inner wall of the cavity. The hollowed-out insulating support assembly supports the power battery in an elevated manner, and a flow gap is formed between the battery and the inner wall of the cavity. Static fluorinated liquid fills the cavity and immerses the power battery. The global refrigerant coupling heat exchange module is connected to an independent closed-loop refrigerant circulation loop. The closed-loop loop passes through the enclosure shell, and indirect heat exchange is completed between the refrigerant and the fluorinated liquid through the heat exchange module. The closed-loop variable temperature control module is linked with the refrigerant circulation loop, collects the temperature of the fluorinated liquid in the cavity in real time, automatically adjusts the refrigerant circulation flow, maintains a constant temperature control range for the fluorinated liquid, and achieves balanced heat dissipation throughout the entire area under high-power fast charging.

2. The composite structure global refrigerant coupled fluorinated liquid thermal management integrated architecture according to claim 1, characterized in that, The outer lightweight thermally conductive alloy (preferably 6061 aluminum alloy) has a sidewall thickness of 0.8-3mm (preferably 1.2mm), and the outer aluminum alloy at the bottom of the cavity is thickened to 1.0-3.2mm (preferably 1.5mm); the PEEK equilateral triangular grid pyramid dot matrix cylinder (the cylinder is 3-10mm high and 1-5mm in diameter, and the PEEK ribs are 1-5mm high and 1-5mm wide, preferably 5mm high, 3mm in diameter, and 2mm high and 2mm wide PEEK ribs) aerogel composite insulation layer has an overall thickness of 3-10mm (preferably 5mm); the aluminum-carbon-aluminum composite inner heat exchange plate is formed by hot pressing three layers from the outside to the inside: 0.3-1mm (preferably 0.6mm) aluminum layer, 0.2-2mm (preferably 1.2mm) carbon fiber substrate, and 1-3mm (preferably 2mm) aluminum layer.

3. The composite structure global refrigerant coupled fluorinated liquid thermal management integrated architecture according to claim 2, characterized in that, The width of the hollow refrigerant channel is 0.5-1.5mm (preferably 1mm), and the interval between two adjacent hollow refrigerant channels is 5-30mm (preferably 20mm); the refrigerant circulation loop adopts any one of the following layouts: single-pipe, double-pipe, or four-pipe connection.

4. The composite structure global refrigerant coupled fluorinated liquid thermal management integrated architecture according to claim 1, characterized in that, The full-area refrigerant coupling heat exchange module is arranged around the shell sidewalls, bottom, and top cover to achieve 360° all-round heat exchange coverage (six-sided full-dimensional heat exchange, including the shell sidewalls, bottom, and top cover).

5. The composite structure global refrigerant coupled fluorinated liquid thermal management integrated architecture according to claim 1, characterized in that, The multi-layered composite enclosure can be divided into one or more independent battery compartments. When two or more battery compartments are set, ultra-thin heat-conducting sheets are installed between the adjacent compartment walls. The two sides of the ultra-thin heat-conducting sheets contact the fluorinated liquid in the compartments on both sides, achieving uniform heat distribution across the entire compartment and reducing the temperature difference of the cells in the whole pack. No heat-conducting sheets are required for a single compartment.

6. The composite structure global refrigerant coupled fluorinated liquid thermal management integrated architecture according to claim 1, characterized in that, The volume ratio of the fluorinated liquid to the power battery cell in the cavity is 1:1.6-1:2.7 (preferably 1:2.05); the safe operating temperature range of the fluorinated liquid covers 17℃~49℃, which can offset the dimensional fluctuations caused by thermal expansion and deformation of the medium.

7. The composite structure global refrigerant coupled fluorinated liquid thermal management integrated architecture according to claim 1, characterized in that, The closed-loop variable frequency temperature control module is configured with a three-level hierarchical working logic: Low temperature operation: When the variable frequency compressor stops, the residual heat of the battery cell is locked in by the PEEK triangular grid pyramid lattice cylindrical aerogel composite insulation layer to maintain the temperature of the fluorinated liquid at no less than 17°C. Normal fast charging conditions: The inverter compressor operates at low power to stably maintain the fluorinated liquid within the optimal constant temperature range of 25℃~35℃ for the battery cell; Ultra-fast charging mode: The inverter compressor operates continuously at full load, and the refrigerant circulates and heats at high speed throughout the entire range, adapting to the heat dissipation requirements of continuous high-power charging from 240kW to 1000kW and above.

8. The composite structure global refrigerant coupled fluorinated liquid thermal management integrated architecture according to claim 7, characterized in that, It also includes an optional low-temperature auxiliary heating component. In low-temperature environments, the heating component can be powered by a solar power component or an auxiliary battery. The heating is stopped after the fluorinated liquid is heated to 25°C. The temperature of the medium inside the chamber is maintained at 10~25°C within the external environment range of -40°C to 60°C.

9. The composite structure global refrigerant coupled fluorinated liquid thermal management integrated architecture according to claim 7, characterized in that, When a single battery cell experiences a thermal anomaly, the variable frequency compressor drives the refrigerant circulation loop at full load and operates at full speed. The 360° (six-sided full-dimensional heat exchange, including the four sides of the casing, bottom, and top cover) three-dimensional heat exchange cavity simultaneously blocks the lateral conduction of heat. Combined with the flame-retardant heat absorption properties of the fluorinated liquid, it prevents the entire package from experiencing a thermal chain reaction caused by a single battery cell failure, thus preventing fires under impact and short-circuit conditions.

10. The composite structure global refrigerant coupled fluorinated liquid thermal management integrated architecture according to claim 1, characterized in that, The entire architecture abandons the first-generation battery box top cover single-sided heat exchange mode, and relies on the synchronous surrounding heat exchange of the outer periphery, bottom and top cover of the battery cell, increasing the heat dissipation capacity to 240-1000kW and above ultra-high power fast charging, which is different from the single-sided heat dissipation box structure that is only compatible with power within 240kW.

11. The composite structure global refrigerant coupled fluorinated liquid thermal management integrated architecture according to claim 1, characterized in that, The hollowed-out insulating support component is a glass fiber reinforced PEEK (GF-PEEK) integral injection molded hollowed-out mesh plate. The mesh hollowed-out size allows for unobstructed flow of fluorinated liquid. The material is insulating and pressure resistant, resistant to fluorinated liquid corrosion, and has low thermal conductivity, so it will not form thermal bridges.

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