Battery Pack Standoff Structure for Immersion Cooling Channels
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Solution Overview
Problem
Existing thermal management systems for traction battery packs in electrified vehicles are inefficient in managing thermal energy due to limitations in coolant flow and support structures, leading to potential overheating and performance issues.
Innovation Solution
The implementation of a traction battery pack assembly with a monolithic enclosure assembly and standoffs that project from the enclosure walls, supporting a support sheet, which establishes coolant channels for immersion cooling, distributing thermal loads, and facilitating efficient coolant circulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional thermal management systems are used with limited coolant flow paths, then the system complexity is reduced, but thermal management efficiency deteriorates leading to overheating
Solution Approach 1:
The battery pack is divided into multiple coolant channels formed by alternating layers of standoffs and support sheets, creating segmented flow paths that increase cooling efficiency without requiring a completely new system architecture
Solution Approach 2:
The standoffs serve multiple functions: they provide structural support to maintain cell spacing, define coolant channel boundaries, and enable thermal management. This multi-functionality improves cooling efficiency without proportionally increasing system complexity
2Productivity
If immersion cooling with direct coolant contact is implemented, then cooling efficiency is improved, but the risk of thermal runaway spreading increases
Solution Approach 1:
The cell stack is segmented by support sheets into discrete sections with coolant channels between them. This segmentation allows efficient immersion cooling while creating physical barriers that can contain thermal runaway events to specific sections
Solution Approach 2:
Support sheets act as intermediary barriers between battery cells, allowing coolant to flow along their surfaces for efficient heat removal while preventing direct flame or thermal contact between adjacent cells, thus mitigating thermal runaway propagation
3Productivity
If standoffs and support sheets are used to create coolant channels, then coolant circulation is improved, but manufacturing complexity increases
Solution Approach 1:
Multiple standoffs are combined into monolithic enclosure assemblies where the standoffs are integrally formed with the enclosure walls. This merging reduces the number of separate components and simplifies assembly while maintaining effective coolant channel geometry
Solution Approach 2:
The support sheets serve dual purposes as both structural support elements and coolant channel boundaries. This multi-functionality reduces the total number of components needed and simplifies the overall manufacturing process while maintaining effective coolant circulation
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 energy management by allowing direct coolant immersion and circulation through defined channels, improving cooling efficiency and reducing the risk of overheating, thereby optimizing battery performance.
Implementation Method 1
liquid coolant can be moved through the traction battery pack to help manage thermal energy within the traction battery pack
Implementation Method 2
immersing at least a portion of a cell stack within a liquid coolant to manage thermal energy within the cell stack
Data Source
AI summary
A traction battery pack assembly includes an enclosure assembly having an enclosure wall. A cell stack is within an interior of the enclosure assembly. The cell stack has one or more battery cells disposed along a cell stack axis. The assembly further includes a support sheet and a plurality of standoffs disposed between the cell stack and an area of the enclosure assembly.