Battery Module Coolant Channels With Temperature-Responsive Flow Control
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Solution Overview
Problem
Existing battery cell cooling systems using static epoxy fillers or solidifying fluids are inefficient in dissipating thermal energy from battery cells, as they provide fixed thermal pathways that do not effectively manage heat dissipation.
Innovation Solution
A battery module design incorporating a preformed insert with coolant channels and a flow control system, featuring flow diverters that adjust based on coolant temperature to manage coolant flow, and a sealed enclosure with a pressure release valve, to enhance thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If static epoxy filler or solidifying fluid is used to provide fixed thermal pathways, then thermal energy can be conducted away from battery cells, but heat dissipation efficiency is relatively inefficient
Solution Approach 1:
The patent replaces static epoxy fillers with a dynamic liquid coolant system that flows through channels. The coolant actively circulates to transfer heat, transforming the cooling system from a passive static structure to an active dynamic system, thereby significantly improving heat dissipation efficiency.
Solution Approach 2:
The patent introduces a liquid coolant flowing through defined channels to replace solid thermal pathways. By utilizing fluid dynamics and hydraulic principles, the system achieves superior thermal conductivity and heat transfer efficiency compared to static solid fillers.
2Temperature
If flow diverters contract in response to high coolant temperature, then coolant flow is restricted to improve cooling, but flow control system complexity increases
Solution Approach 1:
The flow diverters are designed to automatically contract or expand in response to coolant temperature changes without external control. This self-regulating mechanism uses the thermal environment itself to control coolant flow, simplifying the overall system by eliminating the need for external sensors or actuators.
Solution Approach 2:
The flow diverters change their physical state or dimensions in response to temperature parameter changes. As coolant temperature increases, the diverters contract to restrict flow and increase cooling efficiency, creating a feedback loop that automatically optimizes thermal management.
3Temperature
If preformed insert with coolant channels is used, then immersive cooling is achieved, but manufacturing precision requirements increase
Solution Approach 1:
The cooling channels and cell cavities are preformed in the insert before final assembly. This preliminary formation allows for precise channel geometry to be established upfront, ensuring optimal coolant flow paths and thermal contact with battery cells while maintaining manufacturing feasibility.
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 design achieves efficient heat dissipation through immersive cooling, optimizing battery performance and longevity by dynamically controlling coolant flow and pressure, thereby improving thermal conductivity and reducing operating temperatures.
Implementation Method 1
The flow diverters may be configured for contracting from a nominal state to a smaller state in response to a coolant temperature of the coolant flow thereat surpassing a nominal temperature threshold
Implementation Method 2
A battery module with coolant flow control... leveraging thermodynamic benefits of a moving coolant flow to conduct or otherwise thermally transfer heat away from the battery cells
Implementation Method 3
The preformed insert may include a plurality of thermal channels for the battery cells, wherein the thermal channels are configured for retaining a thermal fluid separately from the coolant flow when a coolant temperature of the coolant flow is less than a thermal threshold and for releasing the thermal fluid into the coolant flow when the coolant temperature surpasses the thermal threshold
Data Source
AI summary
A battery module including a plurality of battery cells configured for storing and supplying electrical power, a cell holder configured for supporting the battery cells, a preformed insert including a potting material shaped to define a plurality of coolant channels for the battery cells, and a flow control system operable for controlling a coolant flow through the coolant channels.