Battery Pack Cell-Gap Structures for Immersion Cooling Hot Spots

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Solution Overview

Problem

Existing immersion cooling systems for battery packs face inadequate contact between the immersion fluid and heat-generating components, leading to inefficient cooling and potential hot spots, which can cause device failure and reduce lifespan.

Innovation Solution

Implementing fluid-directing structures within gaps between battery cells to slow fluid velocity and direct it towards heat-generating components, enhancing contact and heat transfer, while reducing the need for bulky cooling systems.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If fluid velocity in gaps between battery cells is high, then cooling system compactness is improved, but fluid contact with heat-generating components is inadequate leading to hot spots

Engineering Contradiction:

Improvecooling system compactnessVSAvoidthermal management effectiveness

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

Fluid-directing structures act as intermediary elements positioned in gaps between battery cells to redirect coolant flow. These structures mediate between the compact cooling system design and the need for effective heat transfer by guiding the fluid toward circumferential edges of battery cells where heat-generating components are located, ensuring adequate contact without requiring a bulky cooling system.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Device complexity

If coolant flow is directed only through gaps between cells, then system simplicity is maintained, but heat transfer efficiency is reduced due to poor contact with heat-generating components

Engineering Contradiction:

Improvecooling system simplicityVSAvoidheat transfer efficiency

Core Design Contradiction:

Device complexityVSTemperature

Solution Approach 1:

The fluid-directing structures create local flow modification zones within the gaps between battery cells. By strategically positioning these structures, the coolant flow is locally redirected toward the circumferential edges of battery cells where thermal management is most critical, enhancing heat transfer efficiency in specific high-heat areas without complicating the overall cooling system design.

Inventive Principle:

Principle #3Local quality

3Reliability

If fluid velocity is decreased to improve contact, then heat transfer is enhanced, but cooling system size increases to accommodate slower flow

Engineering Contradiction:

Improvefluid contact qualityVSAvoidcooling system size

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The fluid-directing structures utilize the vertical dimension within the gaps between battery cells to redirect flow horizontally toward the circumferential edges. This three-dimensional flow management allows the system to maintain compact size while improving contact quality, as the structures guide coolant through the available space in multiple directions rather than requiring a larger overall system volume.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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

Improves thermal management by ensuring better fluid contact with battery cells, reducing the risk of hot spots, and optimizing heat removal, thus extending device lifespan and efficiency.

Implementation Method 1

the structure is configured to decrease a velocity of the fluid in the gap

Methodology Applied

Scientific EffectFluid flow velocity reduction:

Implementation Method 2

The structure is configured to direct the fluid towards a first circumferential edge of the first battery cell and a second circumferential edge of the second battery cell

Methodology Applied

Scientific EffectFluid flow direction control:

Implementation Method 3

One method of cooling battery packs includes positioning one or more cold plates (e.g., water cooled cold plates) adjacent to the battery packs

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 4

Another method of cooling battery packs includes routing a coolant around lithium-ion cells in the battery packs using a system of coolant-filled channels

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS20250337049A1Battery packs, systems, and methods having improved thermal management

Publication Date: 2025.10.30 URBIX INC

AI summary

Battery packs, systems, and methods of implementing improved thermal management are described. A battery pack may include a cell holder, an inlet disposed proximate to a first end of the cell holder, an outlet disposed proximate to a second end of the cell holder, and a fluid flowing between the inlet and the outlet. A first battery cell may be disposed adjacent to a second battery cell in the cell holder. A structure may be disposed in a gap between the first battery cell and the second battery cell. The structure may direct the fluid towards a first circumferential edge of the first battery cell and a second circumferential edge of the second battery cell.