Immersion-Cooled Battery Module Layout for Fast-Charging Heat Control
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Solution Overview
Problem
Existing lithium batteries face challenges in thermal management, particularly during fast-charging, as traditional cooling methods are insufficient to handle the high heat generation, leading to potential failures.
Innovation Solution
A battery module design featuring a frame body with an accommodating space, bare cells, a sealing assembly, and a cooling assembly that includes a liquid inlet pipe and outlet connector, where the inlet pipe extends away from the inlet connector, allowing direct immersion of cells in a heat transfer medium, and an expansion tank to manage pressure, combined with a conductive busbar integrated within a wire harness board for thermal-electrical separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional air cooling and indirect liquid cooling methods are used, then the battery structure is simple, but the thermal management efficiency is insufficient when fast-charging rate reaches 4C or higher
Solution Approach 1:
The patent introduces a heat transfer medium as an intermediary substance that directly contacts the battery cells through the cooling plate to facilitate heat transfer. The cooling assembly includes a liquid inlet pipe, liquid outlet pipe, and heat transfer medium that acts as a mediator between the battery cells and the cooling system, enabling more efficient thermal management compared to traditional air cooling methods.
Solution Approach 2:
The patent employs a liquid-based cooling system using hydraulic principles. The cooling assembly utilizes a liquid inlet pipe and liquid outlet pipe to circulate heat transfer medium through channels in the cooling plate, applying hydraulic flow to achieve efficient heat removal from the battery cells during high-rate fast charging.
2Temperature
If the liquid inlet pipe is connected directly to the liquid outlet connector on the same side, then the device structure is simplified, but the heat transfer medium cannot flow through the accommodating space to achieve effective cooling
Solution Approach 1:
The patent extends the liquid inlet pipe from the front side of the frame body through the accommodating space to the rear side, creating a multi-dimensional flow path. This dimensional extension allows the heat transfer medium to traverse the entire battery module interior, contacting the cells on both sides for effective cooling, rather than simply connecting inlet and outlet on the same side.
Solution Approach 2:
The liquid inlet pipe serves multiple functions: it acts as both an inlet for the heat transfer medium and an extended flow channel that guides the medium through the accommodating space. This multi-functional design allows a single component to achieve both fluid introduction and heat exchange pathway provision.
3Volume of stationary object
If bare cells are arranged densely in the accommodating space, then the battery module volume is reduced, but thermal management becomes more difficult
Solution Approach 1:
The cooling plate with embedded cooling channels acts as an intermediary thermal management component positioned between the densely arranged battery cells. This intermediate cooling structure enables efficient heat removal from multiple cells simultaneously, making dense packing thermally manageable by providing direct thermal contact pathways.
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
Enhances thermal management efficiency by ensuring thorough heat exchange and pressure management, while providing safety through isolation of ejected substances, thus addressing the thermal management challenges and improving battery safety.
Implementation Method 1
the plurality of bare cells are immersed in the heat transfer medium... allowing the heat transfer medium to fully exchange heat with the bare cells
Implementation Method 2
a heat transfer medium is introduced through the liquid inlet connector and guided into the accommodating space via the liquid inlet pipe
Implementation Method 3
an expansion tank to manage pressure
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A battery module, including a frame body, a plurality of bare cells, a sealing assembly and a cooling assembly. The frame body internally has an accommodating space. The bare cells are arranged in the accommodating space. The sealing assembly is connected to the frame body, and is configured to seal the accommodating space. The cooling assembly includes a liquid inlet pipe, a liquid inlet connector and a liquid outlet connector. The liquid inlet connector and the liquid outlet connector are provided on the same outer side of the frame body. The liquid inlet pipe is provided inside the accommodating space. One end of the liquid inlet pipe is connected to the liquid inlet connector, and the other end of the liquid inlet pipe extends to a side of the accommodating space away from the liquid inlet connector. The battery module and the battery pack can address the problem that it is difficult to meet the thermal management requirements of batteries.