Battery Pack Dual-Coolant Assembly for Terminal Isolation and Cooling
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Solution Overview
Problem
Existing thermal management systems for battery packs in electrified vehicles are inefficient in managing thermal energy across diverse components, particularly distinguishing between conductive and non-conductive elements, leading to potential electrical conductivity issues and suboptimal energy management.
Innovation Solution
A dual coolant system is employed within the battery pack, utilizing a dielectric liquid for conductive components and a water/glycol mix for non-conductive components, separated by sealing rings to manage thermal energy efficiently while preventing electrical interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single coolant system is used for all battery pack components, then the system structure is simple, but thermal management efficiency is suboptimal due to inability to differentiate between conductive and non-conductive components
Solution Approach 1:
The battery pack thermal management system is segmented into two distinct coolant systems: a first coolant system for non-conductive components and a second coolant system for conductive components. This segmentation allows each coolant to be optimized for its specific component type, improving thermal management efficiency while maintaining manageable system complexity through functional separation.
2Reliability
If dielectric liquid is used for all components, then electrical conductivity issues are prevented, but thermal management efficiency decreases due to suboptimal heat transfer properties
Solution Approach 1:
Different coolant types are applied to different locations based on electrical conductivity requirements: dielectric liquid is used specifically for non-conductive components where electrical isolation is needed, while conductive coolant is used for conductive components where optimal heat transfer is the priority. This local quality approach ensures both electrical safety and thermal efficiency are optimized at each specific location.
3Productivity
If multiple coolant types are used, then thermal management efficiency improves through optimized heat transfer, but system complexity increases due to additional sealing and circulation requirements
Solution Approach 1:
The thermal management system is divided into separate circulation loops for different coolant types, with dedicated sealing systems and heat exchangers for each. This segmentation reduces the overall complexity compared to a single unified system by allowing independent optimization and maintenance of each coolant circuit, rather than requiring a complex multi-functional single system.
4Reliability
If dielectric liquid contacts conductive components, then electrical safety is maintained, but thermal energy management becomes suboptimal
Solution Approach 1:
The system applies the principle of local quality by matching coolant electrical properties to component electrical characteristics: dielectric liquid is applied specifically to non-conductive components to maintain electrical safety, while conductive coolant is applied to conductive components to achieve optimal thermal energy management. This localized matching ensures both electrical safety and thermal efficiency are maximized at each component interface.
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 coolant system effectively manages thermal energy across various battery pack components, reducing the need for dielectric liquid and enhancing thermal management efficiency by isolating conductive and non-conductive elements, thus improving overall battery performance and safety.
Implementation Method 1
a first coolant within the interior, the first coolant directly contacting the first terminals of the plurality of first battery cells and second terminals of the plurality of second battery cells
Implementation Method 2
a second coolant that manages thermal energy within the interior, the second coolant a different type of coolant than the first coolant
Data Source
AI summary
A traction battery pack assembly includes an enclosure assembly providing an interior, and a first cell stack housed within the interior. The first cell stack includes first battery cells having first terminals. A second cell stack is housed within the interior. The second cell stack includes second battery cells having second terminals. A first coolant is within the interior. The first coolant directly contacts the first terminals of the first battery cells within the first cell stack and second terminals of the second battery cells within the second cell stack. A second coolant manages thermal energy within the interior. The second coolant is a different type of coolant than the first coolant.