Battery Housing Microchannels for Passive Evaporative Cooling
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Solution Overview
Problem
Existing traction battery cooling systems face challenges with weight, cost, and reliability, particularly in high-power applications where large thermal losses occur, leading to potential overheating and safety hazards due to the need for extensive liquid cooling and increased weight and energy consumption.
Innovation Solution
A housing device with microchannel structures in the evaporation device allows for efficient cooling of battery cells by evaporating a dielectric fluid, which absorbs heat from the battery cells, reducing the need for extensive liquid filling and weight, and enabling passive cooling without pumps or compressors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If liquid cooling systems are used to remove heat from high-power batteries, then heat transfer efficiency is improved, but weight and energy consumption increase due to extensive liquid filling and active circulation requirements
Solution Approach 1:
The patent utilizes phase change of dielectric fluid (evaporation and condensation cycles) to transfer heat from battery cells. The fluid evaporates at low temperature absorbing heat from cells, then condenses releasing heat to the environment, providing high heat transfer efficiency without requiring extensive liquid filling or active circulation systems.
Solution Approach 2:
The cooling system operates passively using natural convection and phase change of the dielectric fluid. The evaporated fluid rises naturally to condense, and condensed fluid falls back to evaporate, creating a self-sustaining cooling cycle without pumps or compressors, thereby reducing weight and energy consumption.
2Temperature
If dielectric fluid is used for direct contact cooling of battery cells, then cooling efficiency is improved, but electrical safety risks increase due to potential conductivity
Solution Approach 1:
The patent employs a dielectric fluid that is electrically non-conductive, creating an electrically inert environment between the cooling system and battery cells. This allows direct contact cooling while maintaining electrical safety, as the dielectric fluid prevents any potential electrical conduction between cells and cooling components.
3Temperature
If active circulation systems are implemented to move heat-transfer medium, then heat removal capability is improved, but device complexity and energy consumption increase due to pumps and control systems
Solution Approach 1:
The cooling system operates passively using natural convection and phase change of the dielectric fluid. The evaporated fluid rises naturally to condense, and condensed fluid falls back to evaporate, creating a self-sustaining cooling cycle without pumps or compressors, thereby reducing weight and energy consumption.
Solution Approach 2:
The patent replaces mechanical circulation systems (pumps, motors) with passive thermal convection and phase change mechanisms. The heat transfer is achieved through natural buoyancy-driven flow of evaporated and condensed fluid, eliminating complex mechanical components while maintaining effective heat removal.
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 provides effective heat transfer and cooling of high-power battery cells with reduced weight and energy consumption, maintaining the battery cells within a safe temperature range and preventing overheating, thus enhancing safety and efficiency.
Implementation Method 1
heat is transferred from the battery cells to the liquid fluid in the microchannels, whereby the liquid fluid evaporates in the evaporation device
Implementation Method 2
heat is transferred from the battery cells to the liquid fluid in the microchannels
Implementation Method 3
the liquid fluid enters the microchannels through the at least one inlet opening and heat is transferred from the battery cells to the liquid fluid in the microchannels
Data Source
AI summary
A housing device for a traction battery with fluid-based cooling in a vehicle. The traction battery has a plurality of a battery cells. The housing device includes a housing body, which forms an enclosed interior with a plurality of receiving positions for receiving the plurality of battery cells and a bottom region of which is designed to receive liquid fluid. An evaporation device is included for evaporating the liquid fluid. The evaporation device has a plurality of microchannel structures for forming microchannels. The microchannel structures extend in a vertical direction in the assembled state and have, in their lower region with respect to the vertical direction, at least one inlet opening for receiving liquid fluid from the bottom region of the housing body. During operation, liquid fluid enters the microchannels through the at least one inlet opening and heat is transferred from the battery cells to the liquid fluid in the microchannels. The liquid fluid evaporates in the evaporation device. A traction battery for a vehicle with fluid-based cooling includes a housing device as described above.