Immersion-Cooled Battery Array Venting With Isolated Flow Paths

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Solution Overview

Problem

Existing electrified vehicle traction battery packs face challenges in managing thermal energy levels effectively, particularly in preventing convective heat transfer and overheating during thermal events, which can affect the performance and safety of battery cells.

Innovation Solution

A battery array design with fluidly isolated cooling fluid flow paths and vent flow gas paths, utilizing a middle cooling plate to subdivide the interior volume and separate battery cells, along with dedicated vent gas paths to manage thermal byproducts independently of the cooling fluid flow, ensuring minimal thermal interference between cells.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If battery cells are arranged in a conventional configuration without fluid isolation, then the device complexity is reduced, but convective heat transfer between cells occurs causing overheating during thermal events

Engineering Contradiction:

Improvethermal management effectivenessVSAvoidcooling system structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The interior volume is subdivided into multiple fluidly isolated cooling fluid flow paths using partition walls, with each path dedicated to specific battery cells. This segmentation prevents convective heat transfer between adjacent cells while maintaining effective thermal management through isolated cooling circuits.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A dielectric cooling fluid is introduced as an intermediary substance that transfers heat from battery cells to cooling plates without conducting electricity. The fluid circulates through isolated paths, enabling thermal energy removal while preventing harmful convective heat transfer between cells during thermal events.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If vent byproducts are mixed with cooling fluid in the same flow path, then the device complexity is reduced, but the cooling fluid becomes contaminated and thermal management efficiency decreases

Engineering Contradiction:

Improvecooling fluid effectivenessVSAvoidflow path configuration

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The system is divided into separate functional zones: cooling fluid flow paths for thermal management and vent flow gas paths for byproduct removal. This segmentation ensures that vent byproducts never contaminate the cooling fluid, maintaining cooling effectiveness while managing thermal events safely.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The venting function is extracted from the cooling system by creating independent vent flow gas paths that separate from the cooling fluid paths. Vent byproducts are removed through dedicated exhaust runners and manifolds, preventing contamination of the cooling fluid while maintaining efficient thermal management.

Inventive Principle:

Principle #2Taking out (Extraction)

3Device complexity

If adjacent battery cells are allowed to share the same cooling fluid flow path, then the device complexity is reduced, but thermal interference between cells increases during thermal events

Engineering Contradiction:

Improvecooling system designVSAvoidconvective heat transfer between cells

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

Partition walls create separate cooling fluid flow paths for adjacent battery cells, preventing convective heat transfer between them. Each cell or cell group has its own isolated cooling circuit, eliminating thermal interference during thermal events while maintaining manageable system complexity through modular design.

Inventive Principle:

Principle #1Segmentation

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution enhances thermal management by maximizing heat transfer from battery cells while isolating vent byproducts, preventing overheating and reducing convective heat transfer, thereby improving the safety and performance of the battery pack.

Implementation Method 1

intake manifold configured to receive a cooling fluid for immersion cooling the first battery cell

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 2

fluidly isolated cooling fluid flow paths and vent flow gas paths

Methodology Applied

Scientific EffectFluid isolation:

Data Source

PatentUS20250246715A1Battery array designs for immersion cooling and venting systems

Publication Date: 2025.07.31 FORD GLOBAL TECH LLC

AI summary

Immersion cooling and venting systems are provided for managing thermal energy levels of traction battery packs. A battery array of the traction battery pack may be configured to establish fluidly isolated cooling fluid flow paths and vent flow gas paths. A cooling fluid (e.g., a dielectric) may be communicated through the cooling fluid flow paths for immersion cooling battery cells of the battery array. The vent flow gas paths may be established by battery holders and battery stands that space the battery cells apart from a middle cooling plate of the battery array.