Vehicle Battery Coolant Reservoir Layout for Uniform Cell Cooling
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Solution Overview
Problem
Existing vehicle battery packs face challenges in effectively controlling operating temperatures due to space constraints, leading to potential overheating and de-rating of the battery pack, especially under heavy loads and varying environmental conditions.
Innovation Solution
The battery assembly incorporates a housing with interconnected first and second containers, where the housing and first container are filled with coolant fluid, and the second container is part-filled with coolant and gas, allowing for thermal expansion and contraction while maintaining all cells submerged in coolant, even under mechanical forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the battery pack is designed to maximize cell density in limited space, then the storage capacity and energy density are improved, but the ability to control operating temperature of cells deteriorates due to insufficient coolant circulation space
Solution Approach 1:
The coolant container is divided into a first container and a second container. The first container is integrated with the housing and contains battery cells, while the second container is separate and connected via a connection channel. This segmentation allows the coolant to be distributed more effectively, ensuring all cells are submerged while maintaining adequate coolant circulation space for temperature control.
Solution Approach 2:
The connection channel between the first and second containers extends in a direction transverse to the longitudinal axis of the battery pack, utilizing horizontal space rather than vertical space. This dimensional approach maximizes cell density in the vertical direction while maintaining coolant circulation pathways in the horizontal plane, resolving the conflict between energy density and thermal management.
2Temperature
If the housing is completely filled with coolant fluid to ensure all cells are covered, then temperature control is improved, but the volume for thermal expansion and contraction is reduced
Solution Approach 1:
The coolant system is segmented into two containers. The first container is filled with coolant to submerge all battery cells for effective temperature control. The second container contains the remaining coolant and provides the necessary volume for thermal expansion and contraction, as well as for gas separation.
Solution Approach 2:
The connection channel acts as an intermediary between the first and second containers, allowing coolant to flow between them while maintaining pressure equilibrium. This intermediary structure enables the system to accommodate thermal expansion and contraction without compromising the submersion of cells in the first container.
3Temperature
If internal baffles are added to the housing to improve coolant distribution, then temperature uniformity is improved, but the available space for battery cells is reduced
Solution Approach 1:
Instead of adding baffles within the housing, the system segments the coolant container into two separate containers. The first container provides uninterrupted coolant access to all battery cells, ensuring temperature uniformity without requiring internal partitions that would reduce cell capacity.
Solution Approach 2:
The connection channel serves as an intermediary coolant pathway that distributes coolant between the first and second containers. This external distribution system achieves temperature uniformity without intruding into the battery cell arrangement space within the housing.
4Volume of stationary object
If the cross-sectional area of the connection channel is minimized to reduce space, then the volume occupied is reduced, but the pressure transient dissipation capability is weakened
Solution Approach 1:
A burst disc is pre-installed in the connection channel at a location that provides sufficient dissipation capacity. This preliminary safety measure ensures that when pressure transients occur during thermal events, the burst disc can rapidly expand to provide adequate pressure relief, compensating for the limited volume of the narrow connection channel.
Solution Approach 2:
The burst disc acts as an intermediary safety device within the connection channel. It maintains the narrow channel dimensions for space efficiency while providing the necessary pressure transient dissipation capability when activated, balancing the conflicting requirements of compactness and pressure management.
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
This design ensures that all battery cells remain covered with coolant, minimizing temperature differences and preventing overheating, thus reducing the need for spare capacity and resulting in a lighter and more compact battery pack.
Implementation Method 1
a housing, for containing a coolant fluid and at least one battery cell to be cooled by said coolant fluid
Implementation Method 2
the lower portion of the first container volume is in fluid communication with an upper portion of the housing
Implementation Method 3
the second container is part-filled with coolant and gas, allowing for thermal expansion and contraction
Data Source
AI summary
The present disclosure relates to a battery assembly for a vehicle such as an electric vehicle or a hybrid electric vehicle, and to methods associated with such an assembly. As disclosed, there is provided a battery assembly for a vehicle, the assembly having a housing, the housing for containing a coolant fluid and at least one battery cell to be cooled by said coolant fluid, the assembly further having a first container volume having a lower portion in fluid communication with an upper portion of the housing, wherein the first container volume has a smaller cross-sectional area in a horizontal plane than that of the housing, and the assembly further having a second container volume having a lower portion in fluid communication with an upper portion of the first container volume. The disclosed battery assembly provides improved battery performance by virtue of improved cell temperature management, particularly when packaging is constrained.