Immersion-Cooled Battery Enclosure with Dual-Tier Flow Guides
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Solution Overview
Problem
Existing thermal management systems for battery arrays in electrified vehicles face challenges in efficiently cooling the battery cells while maintaining mechanical support, due to limited coolant flow channels and space constraints.
Innovation Solution
A battery array enclosure structure with dual-tier guide features, comprising elongated bodies and discrete dimples, that provide mechanical support and enhance coolant flow, increasing turbulence and contact area for improved cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional single-tier cooling structures are used, then the structure is simple, but the cooling efficiency is insufficient due to limited coolant flow channels
Solution Approach 1:
The cooling structure is segmented into two distinct tiers: a first tier with elongated bodies forming primary coolant flow channels, and a second tier with discrete protrusions forming secondary coolant flow channels. This segmentation creates multiple independent cooling pathways that increase overall cooling efficiency while maintaining manufacturing simplicity through modular design
Solution Approach 2:
The invention transitions from a single-plane cooling structure to a dual-tier three-dimensional configuration. The first tier elongated bodies extend in one dimension while the second tier discrete protrusions extend in another dimension, creating multi-directional coolant flow paths that significantly enhance cooling efficiency without complicating the manufacturing process
2Productivity
If coolant flow channels are increased to improve cooling, then cooling efficiency improves, but pressure drop increases affecting pump performance
Solution Approach 1:
The first tier elongated bodies and second tier discrete protrusions are strategically positioned at different locations within the battery array enclosure. The elongated bodies provide primary cooling zones while the discrete protrusions create secondary cooling zones, allowing localized heat management that improves overall cooling efficiency while distributing pressure drop across multiple regions rather than concentrating it in single channels
3Productivity
If more cooling features are added, then cooling efficiency improves, but mechanical support capability may be compromised
Solution Approach 1:
The first tier elongated bodies and second tier discrete protrusions are designed to serve dual functions: they create coolant flow channels for thermal management while simultaneously providing structural support for the battery cells. This multi-functionality ensures that cooling efficiency is enhanced without compromising the mechanical support capability needed to hold battery cells in place
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 dual-tier guide features enhance cooling efficiency by 7% and maintain mechanical support, while minimizing pressure drop impact on coolant pump performance.
Implementation Method 1
enhance coolant flow, increasing turbulence and contact area for improved cooling efficiency
Implementation Method 2
improved cooling efficiency by 7%
Data Source
AI summary
An assembly includes a first housing component and a second housing component cooperating with the first housing component to provide an enclosed internal cavity. At least one cell stack includes one or more battery cells that are positioned within the enclosed internal cavity. A first plurality of guide features are formed on at least one of the first housing component and the second housing component, and a second plurality of guide features are formed on the at least one of the first housing component and the second housing component.