BATTERY KIT WITH A COOLING PLATE

Abstract

A battery pack (200) comprises a plurality of cells (202) and a cooling plate (204) designed to absorb heat generated in the plurality of cells (202). The cooling plate (204) comprises a flat first plate (206) and a second plate (208) with a corrugated cross-section (210) such that, when the second plate (208) is mounted above the first plate (206), the corrugated cross-section (210) defines a plurality of interconnected flow channels (212) for the flow of a cooling fluid along a length of the flow channels (212). Additionally, the cooling plate (204) includes serpentine plates (214) arranged vertically within the plurality of flow channels (212) and extending along the length of the flow channels (212) to generate turbulence in the flow of the cooling fluid as the cooling fluid moves along the length of the flow channels (212).

Description

TECHNICAL AREA

[0001] The present disclosure relates generally to the technical field of electrical energy storage systems in motor vehicles. In particular, it relates to a battery pack with an improved cooling plate for cooling the battery pack. BACKGROUND

[0002] Battery packs are crucial for storing and delivering electrical energy in various applications, particularly in electric vehicles (EVs) and electronic devices. In the automotive industry, battery packs consisting of multiple cylindrical lithium-ion cells are essential for powering electric vehicles. However, during operation, these battery packs generate significant heat due to electrochemical reactions within the cells. Excessive heat can lead to reduced battery performance, a shorter lifespan, and potential safety hazards.

[0003] To overcome these challenges, various cooling solutions have been developed, ranging from liquid cooling systems to air-cooled designs. One of the liquid cooling systems used to cool battery packs is a cooling plate. As in Fig. As shown in Figure 1, for example, a cooling plate 100 is arranged within the battery pack to cool the cells of the battery pack. The cooling plate 100 comprises a first plate 102 and a second plate 104 with an undulating structure. When the second plate 104 is mounted above the first plate 102, the undulating structure forms a multitude of coolant flow channels 106 to allow the flow of a coolant along a certain length of the coolant flow channels 106. The cooling plate 100 can be in direct contact with the cells of the battery pack to transfer heat from the cells to the coolant. The coolant absorbs the heat generated by the battery and releases it to the environment. In this way, the cooling plate 100 maintains an optimal temperature within the battery pack.

[0004] However, the 100 cooling plates do not offer sufficient surface area for adequate heat absorption from the cells. This limitation can lead to elevated temperatures within the battery pack, which impairs performance, shortens lifespan, and potentially poses a safety risk.

[0005] In the field of engineering, efforts have been made to improve the cooling efficiency of battery pack cooling plates. For example, patent document CN218975566U discloses a cooling plate equipped with a plurality of flow channels extending along its length. These channels carry a coolant to absorb the heat generated by the battery. Furthermore, the cooling plate incorporates a turbulence structure located on the inner wall of the flow channel within the cooling plate. This turbulence structure forms a helical groove oriented along the direction of the flow channel.The turbulence structure within the flow channel creates turbulence in the coolant to prevent the formation of hot layers near the inner surface of the side in contact with the cells, which can impair heat transfer from the cells to the coolant and thus the heat absorption performance of the cooling plate.

[0006] While the aforementioned patent discloses an arrangement for improving the heat transfer absorption of a cooling plate by generating turbulence in the coolant flow, it is possible to provide a more cost-effective and efficient arrangement that can improve the heat transfer absorption of a cooling plate of a battery pack.

[0007] Therefore, there is a need for a battery pack with an improved cooling mechanism based on an improved cooling plate. OBJECTS OF INVENTION

[0008] A general objective of the present disclosure is to provide an improved cooling plate that offers improved heat absorption capability.

[0009] One objective of the present disclosure is to provide an improved cooling plate that optimizes heat absorption performance by maintaining a healthy temperature difference between the heat absorption area of ​​the cooling plate and the adjacent coolant.

[0010] Another objective of the present disclosure is to provide an improved cooling plate that is easier and cheaper to manufacture.

[0011] Another objective of the present disclosure is to provide an improved cooling plate that significantly improves the heat transfer efficiency within a given size and at given flow rates of the cooling fluid. SUMMARY

[0012] Aspects of the present disclosure relate to electrical energy storage systems, such as a battery pack, in motor vehicles. In particular, it relates to a cooling plate for regulating the temperature within a vehicle's battery pack, ensuring optimal performance and longevity of the battery pack.

[0013] In one aspect, the present disclosure provides a battery assembly comprising a plurality of cells and a cooling plate designed to absorb the heat generated in the plurality of cells. The cooling plate comprises a generally flat first plate and a second plate with a corrugated cross-section such that, when the second plate is mounted above the first plate, the corrugated cross-section defines a plurality of interconnected flow channels for the flow of a cooling fluid along a length of the flow channels. Additionally, the battery assembly includes serpentine plates arranged vertically within the plurality of flow channels and extending along the length of the flow channels to generate turbulence in the flow of the cooling fluid as the cooling fluid moves along the length of the flow channels.

[0014] In one aspect, the corrugated cross-section can contain a series of alternating flat elevations and depressions. The flat tip may exhibit a serpentine ridge along the length of the flow channels. The shape of the serpentine ridge may correspond to the serpentine plate.

[0015] In one aspect, the serpentine ridge can be designed in such a way that it holds a corresponding side of the serpentine plate in order to keep the serpentine plate in position.

[0016] In one aspect, the surface of the first plate of the cooling plate can be in direct contact with the multitude of cells in order to transfer heat from the multitude of cells to the cooling fluid.

[0017] In one aspect, the cooling plate can contain at least one inlet opening and at least one outlet opening for the inflow and outflow of the cooling fluid.

[0018] In one aspect, the at least one inlet opening and the at least one outlet opening can be in fluid connection with the flow channels to enable a continuous circulation of the cooling fluid through the flow channels.

[0019] In one aspect, the second plate and the flat first plate can be securely fastened together by any or a combination of welding, gluing or mechanical fastenings to create a tight connection between the flat plate and the second plate.

[0020] In another aspect, the present disclosure provides a cooling plate comprising a flat first plate and a second plate with a corrugated cross-section, such that when the second plate is mounted above the first plate, the corrugated cross-section defines a plurality of interconnected flow channels for the flow of a cooling fluid along a length of the flow channels. Additionally, the cooling plate includes serpentine plates arranged vertically within the plurality of flow channels and extending along the length of the flow channels to generate turbulence in the flow of the cooling fluid as the cooling fluid moves along the length of the flow channels.

[0021] In one aspect, the corrugated cross-section can comprise a series of alternating flat elevations and depressions. The flat tip may exhibit a serpentine ridge along the length of the flow channels. The shape of the serpentine ridge may correspond to the serpentine plate.

[0022] In one aspect, the ridge can be designed in such a way that it securely holds a corresponding side of the serpentine plate in order to keep the serpentine plate in position.

[0023] Various objects, features, aspects and advantages of the invention will become clearer from the following detailed description of preferred embodiments together with the accompanying drawings, in which the same numbers represent the same components. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The accompanying drawings serve to further understand the present disclosure and are an integral part of this description. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure. Fig. Figure 1 shows different views of a conventional cooling plate based on a flat plate and a second plate with a corrugated cross-section, defining a multitude of channels for the flow of a cooling fluid. Fig. Figure 2 shows an exemplary perspective view of the proposed cooling plate with a serpentine plate located inside the channels to generate turbulence, in accordance with embodiments of the present disclosure. Fig. Figure 3A shows an exemplary perspective sectional view of the cooling plate of Fig. 2, showing the details of the serpentine plate located between the flat plate and the second plate with a corrugated cross-section, in accordance with embodiments of the present disclosure. Fig. Figure 3B shows an exemplary cross-sectional view of the cooling plate with the second plate partially removed to show the serpentine plate located above the flat plate, in accordance with embodiments of the present disclosure. Fig. Figure 3C shows an exemplary front view of a channel of the cooling plate, showing the serpentine plate supported by a ridge provided on a flat tip of the corrugated cross-section of the second plate, in accordance with embodiments of the present disclosure Fig. Figure 3D shows an exemplary view of a channel of the cooling plate, which shows turbulence in the flow of the cooling fluid caused by the serpentine plate according to the embodiments of the present disclosure. DETAILED DESCRIPTION

[0025] A detailed description of the embodiments of the disclosure illustrated in the accompanying drawings follows. The embodiments are described in sufficient detail to clearly convey the disclosure. However, the intention is not to limit foreseeable variations of the embodiments with the necessary level of detail; rather, the aim is to cover all modifications, equivalents, and alternatives that fall within the spirit and scope of the present disclosure as defined by the accompanying claims.

[0026] In one embodiment, the present disclosure relates to electrical energy storage systems, such as a battery pack, in motor vehicles. In particular, it relates to a cooling plate for regulating the temperature within a vehicle's battery pack, thereby ensuring optimal performance and longevity of the battery pack.

[0027] In one embodiment, the battery pack comprises a plurality of cells and a cooling plate designed to absorb the heat generated by the plurality of cells. A typical cooling plate comprises a network of interconnected flow channels through which coolant flows to absorb the heat from the cells of the battery pack. Typically, the cooling plates with a plurality of channels are formed from a flat first plate and a second plate with a corrugated cross-section (the second plate is accordingly referred to here as the corrugated plate), such that when the second plate is attached to the first plate, the corrugated structure forms the network of interconnected flow channels for the flow of coolant along its length.

[0028] However, such cooling plates have the disadvantage that the coolant flowing uniformly through the channels tends to form layers of coolant at different temperatures (or a temperature gradient), with the coolant closer to the plate in contact with the cells (referred to here as the heat-conducting plate) having a higher temperature than the coolant farther away. Since the heat transfer from a first medium to a second medium is proportional to the temperature difference between the two, the presence of a higher-temperature coolant (second medium) next to the heat-conducting plate reduces the heat absorption capacity of the cooling plate.

[0029] The present disclosure overcomes the aforementioned limitation of the conventional cooling plate by providing means for generating turbulence in the flow of the coolant through the channels. The disclosed cooling plate comprises a serpentine plate arranged vertically within the plurality of flow channels and extending along the length of the flow channels to generate turbulence in the flow. The generated turbulence results in mixing of the coolant, thereby preventing the formation of layers with different temperatures or temperature gradients. This mixing of the coolant causes the temperature of the coolant adjacent to the heat-conducting plate to decrease, thus improving heat transfer due to the greater temperature difference between the heat-conducting plate and the coolant.

[0030] Another advantage of the serpentine plates is that the coolant takes a longer flow path through the serpentine plates, thus allowing more time for contact between the coolant and the heat-conducting plate to enable heat transfer.

[0031] In one embodiment, the serpentine plate is supported by a serpentine ridge provided on a flat tip of the corrugated plate. The serpentine ridge can be formed during a single pressing operation, in which the corrugated shape and the ridge are combined on the flat tip of the corrugated plate. This eliminates the additional step of forming the ridge, making the production of the proposed cooling plate economical.

[0032] With reference to Fig. Figure 2, in which a schematic perspective view of the proposed battery assembly 200 is disclosed, shows that the battery assembly 200 comprises a plurality of cells 202 and a cooling plate 204 suitable for absorbing the heat generated in the plurality of cells 202. The cooling plate 204 comprises a flat first plate 206 and a second plate 208 with a corrugated cross-section 210, such that when the second plate 208 is mounted above the first plate 206, the corrugated cross-section 210 defines a plurality of interconnected flow channels 212 for the flow of a cooling fluid along a length of the flow channels 212.Additionally, the battery set 200 includes a serpentine plate 214, which is arranged vertically within the plurality of flow channels 212 and extends along the length of the flow channels 212 to generate turbulence in the flow of the coolant as the coolant moves along the length of the flow channels 212.

[0033] In one embodiment, the corrugated cross-section 210 can have alternating flat peaks 216-1 and troughs 216-2. The flat peak 216-1 can have a serpentine ridge 218 along the length of the flow channels 212. The serpentine ridge 218 can have the same shape as the serpentine plate 214. Alternatively, the serpentine container can be made of a flexible material so that a plate made of the elastic material can be connected to the serpentine ridge, allowing the plate to assume the shape of the serpentine ridge.

[0034] Furthermore, the serpentine ridge 218 can be designed to securely hold a corresponding side of the serpentine plate 214 in position. After the serpentine plate 214 has been attached to the second plate / corrugated plate 208, the recesses 216-2 of the second plate / corrugated plate 208 can be welded to the flat first plate 206 to form a series of alternating flow channels 212 for the flow of coolant through the flow channels 212.

[0035] As from Fig. As can be seen in Figure 2, one longitudinal side of the serpentine plate 214 is located at flat tips, such as the flat tip 216-1, of the corrugated cross-section 210 of the second plate 208. It can further be seen that both the corrugated cross-section 210 of the second plate 208 with the serpentine ridge 218 at the flat tips 216-1 and the serpentine plate 214 can be formed by a pressing process, which is a simple and cost-effective manufacturing method for mass production. This makes the proposed cooling plate 204 simple and cost-effective to manufacture compared to known methods for providing means of generating turbulence in the flow channels.

[0036] In one embodiment, the second plate 208 and the flat first plate 206 can be securely fastened together by any or a combination of welding methods, such as electrical spot resistance welding, bonding, or mechanical fastening, to prevent leakage or contamination of the coolant in the cooling plate 204. In another embodiment, the surface of the first plate 206 of the cooling plate 204 can be in direct contact with the plurality of cells 202 to transfer heat from the plurality of cells 202 to the coolant. The direct contact between the flat first plate 206 and the plurality of cells 202 ensures thermal conductivity and improves overall heat dissipation.

[0037] In one embodiment, the cooling plate 204 can be arranged between a lower end of the plurality of cells 202 and a battery housing to maintain the temperature within the battery pack 200. The cooling plate 204 can regulate the temperature of the battery pack 200 to optimize its performance and service life.

[0038] In one embodiment, the cooling plate 204 can comprise at least one inlet opening and at least one outlet opening for the inflow and outflow of the coolant. The at least one inlet opening and the at least one outlet opening can be fluidically coupled to the flow channels 212 to enable continuous circulation of the coolant through the flow channels 212. The continuous flow of the coolant optimizes the cooling of the cooling plate 204 by dissipating heat from the plurality of cells 202.

[0039] Referring to Fig. In 3A to 3C, the cooling plate 204 comprises a flat first plate 206 and a second plate 208 with a corrugated cross-section 210, such that when the second plate 208 is mounted above the first plate 206, the corrugated cross-section 210 defines a plurality of interconnected flow channels 212 for a flow of coolant along a length of the flow channels 212. Additionally, the battery assembly 200 comprises a serpentine plate 214, which is arranged vertically within the plurality of flow channels 212 and extends along the length of the flow channels 212 to generate turbulence in the flow of coolant as the coolant moves along the length of the flow channels 212.

[0040] In one embodiment, the corrugated cross-section 210 can have alternating flat peaks 216-1 and troughs 216-2. The flat peak 216-1 can have a serpentine ridge 218 along the length of the flow channels 212. The serpentine ridge 218 corresponds in shape to the serpentine plate 214. Furthermore, the serpentine ridge 218 can be designed to engage a corresponding side of the serpentine plate 214 in order to hold the serpentine plate 214 in a predefined position.

[0041] In one embodiment, the surface of the first plate 206 of the cooling plate 204 can be in direct contact with the plurality of cells 202 in order to transfer heat from the plurality of cells 202 to the cooling fluid.

[0042] In one embodiment, the serpentine plate 214 can be positioned in each of the flow channels 212 such that it is evenly distributed across the individual flow channels 212 to maximize the surface area for the coolant. The serpentine plate 214 can be securely attached to the corresponding side of the plate 214 to hold it in a predefined position by any or a combination of welding, adhesive, or mechanical fasteners.

[0043] In one embodiment, the serpentine ridge 218 can be positioned along the length of the flow channels 212. The serpentine ridge 218 can mirror the shape of the serpentine plate 214 and, by conforming to the contours of the serpentine plate 214, ensure precise alignment and secure attachment. Thus, the ridge 218 acts as an anchor, holding the serpentine plate 214 in a predefined position within the flow channel 212. This arrangement not only optimizes the structural integrity of the cooling plate 204 but also facilitates efficient fluid flow by maintaining the desired configuration of the serpentine plate 214. Through this careful integration of form and function, the serpentine ridge 218 contributes to the overall stability and performance of the compression-ignition engine, thereby increasing its operational reliability and efficiency.

[0044] In Fig.The 3D image shows an exemplary cross-sectional view of the cooling plate, illustrating the turbulence of the coolant caused by the serpentine plate 214. When the coolant comes into contact with the serpentine plate 214, the flow of the coolant becomes turbulent, which facilitates the mixing of the heated and unheated coolant and thus prevents the accumulation of the heated coolant next to the first plate 206, which can be detrimental to efficient heat transfer from the first plate to the coolant.

[0045] In one embodiment, a basic calculation is performed to determine the Nusselt number: Nu=hDhk Where: D h = hydraulic diameter, mm N u = Nusselt number k = thermal conductivity, W / mK h = Convective heat transfer coefficient, W / m².K

[0046] The serpentine structure of plate 214 can increase the turbulence level for a given coolant flow rate, leading to an increase in the Reynolds number as the initial force increases. Furthermore, the Reynolds number is directly proportional to the Nusselt number, which measures convective heat transfer, which is itself directly proportional to the Reynolds number. Consequently, the serpentine plate 214 enhances convective heat transfer, demonstrating that the heat transfer is superior to that of a straight channel, as can be verified by calculations based on the formulas below: Re=ρuLμ Where: Re = Reynolds number ρ = density of the liquid u = velocity flow L = Characteristic linear measure µ = Dynamic viscosity of the liquid

[0047] Relationship between the Reynolds number, the Prandtl number and the Nusselt number of heat transfer: Nu=CRem Prn=hDk Where: Re = Reynolds number N u = Nusselt number P r = Nusselt number h = heat transfer coefficient (W / m²) 2 k) D = Inner diameter of the pipe

[0048] Based on the calculation, the serpentine plate 214 can be designed to improve the heat transfer from the multitude of cells 202 to the cooling plate 204.

[0049] In one embodiment, the cooling plate 204 improves the heat absorption efficiency for the cooling fluid in the flow passages / channels, optimizes the surface for efficient heat dissipation, ensures adequate cooling for battery sets to mitigate risks, promotes a uniform temperature distribution over the surface of the battery set, and prevents the formation of hot spots within the battery set.

[0050] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention can be developed without deviating from the fundamental scope of the invention. The scope of the invention is defined by the following claims. The invention is not limited to the described embodiments, variants, or examples that enable a person with normal technical knowledge to manufacture and use the invention when combined with information and knowledge available to that person. ADVANTAGES OF THE INVENTION

[0051] The present disclosure provides an improved cooling plate that offers improved heat absorption performance.

[0052] The present disclosure provides an improved cooling plate that optimizes the efficiency of heat absorption by maintaining a healthy temperature difference between the heat absorption area of ​​the cooling plate and the adjacent coolant.

[0053] The present disclosure offers an improved cooling plate that is easier and less expensive to manufacture.

[0054] The present disclosure provides an improved cooling plate that significantly improves the heat transfer efficiency within a given size and at given coolant flow rates. QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] CN 218975566U

[0005]

Claims

[1] Battery pack (200) comprising the following; a large number of cells (202); a cooling plate (204) designed to absorb the heat generated in the plurality of cells (202), the cooling plate (204) comprising: a flat first plate (206); a second plate (208) with a corrugated cross-section (210) such that, when the second plate (208) is mounted over the first plate (206), the corrugated cross-section (210) defines a plurality of interconnected flow channels (212) for the flow of a cooling fluid along a length of the flow channels (212); and a serpentine plate (214) arranged vertically within the plurality of flow channels (212) and extending along the length of the flow channels (212) to generate turbulence in the flow of the cooling fluid as the cooling fluid moves along the length of the flow channels (212). [2] Battery assembly (200) according to claim 1, wherein the corrugated cross-section (210) has alternating flat tips (216-1) and troughs (216-2), wherein the flat tip (216-1) has a serpentine ridge (218) along the length of the flow channels (212), wherein the serpentine ridge (218) corresponds in shape to the serpentine plate (214). [3] Battery assembly (200) according to claim 2, wherein the serpentine ridge (218) is suitable to securely hold a corresponding side of the serpentine plate (214) in order to hold the serpentine plate (214) in a predefined position. [4] Battery pack (200) according to claim 1, wherein the surface of the first plate (206) of the cooling plate (204) is in direct contact with the plurality of cells (202) to transfer heat from the plurality of cells (202) to the cooling liquid. [5] Battery set (200) according to claim 1, wherein the cooling plate (204) comprises at least one inlet opening and at least one outlet opening for the inflow and outflow of the cooling fluid. [6] Battery set (200) according to claim 4, wherein the at least one inlet opening and the at least one outlet opening are in fluid communication with the flow channels (212) for a continuous circulation of the coolant through the flow channels (212). [7] Battery assembly (200) according to claim 1, wherein the second plate (208) and the flat first plate (206) are securely fastened to each other by any or a combination of welding, gluing or mechanical fastening. [8] Cooling plate (204) comprising the following: a flat first plate (206); a second plate (208) with a corrugated cross-section (210) such that, when the second plate (208) is mounted over the first plate (206), the corrugated cross-section (210) defines a plurality of interconnected flow channels (212) for the flow of a cooling fluid along a length of the flow channels (212); and a serpentine plate (214) arranged vertically within the plurality of flow channels (212) and extending along the length of the flow channels (212) to generate turbulence in the flow of the cooling fluid as the cooling fluid moves along the length of the flow channels (212). [9] Cooling plate (204) according to claim 8, wherein the corrugated cross-section (210) comprises alternating flat peaks (216-1) and troughs (216-2), wherein the flat peak (216-1) comprises a serpentine ridge (218) along the length of the flow channels (212), wherein the serpentine ridge (218) corresponds in shape to the serpentine plate (214). [10] Cooling plate (204) according to claim 9, wherein the serpentine ridge (218) is designed to securely hold a corresponding side of the serpentine plate (214) in order to hold the serpentine plate (214) in a predefined position.

Images