Capillary Refrigerant Battery Module Cooling Without Cooling Plates
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Solution Overview
Problem
Existing battery modules face challenges in efficiently cooling battery cells due to high internal resistances and temperature increases during charging and discharging, which can lead to reduced battery life, damage, and uncontrolled reactions, while conventional cooling methods like fluid circulation and cooling plates are costly and require complex thermal contact.
Innovation Solution
A battery assembly with a capillary assembly that externally abuts battery cells, allowing liquid refrigerant to evaporate and escape, creating a closed-loop cooling system within the module, which enhances heat dissipation without the need for direct contact or complex fluid circulation, using materials like metal foams or titanium sponge for efficient capillary transport and heat conduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling plates or fluid circulation systems are used to cool battery cells, then cooling capacity is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The battery cell housing serves its own cooling function by incorporating the cooling channel directly into the housing structure. The housing itself becomes the cooling device, eliminating the need for separate cooling plates or external fluid circulation systems. This self-service approach reduces device complexity while maintaining effective cooling capacity.
Solution Approach 2:
The cooling function is merged with the battery cell housing structure. The housing is designed to include an integrated cooling channel that circulates cooling medium, combining the structural housing function with the thermal management function into a single component, thereby reducing overall system complexity.
2Temperature
If cooling plates are used to cool battery cells, then cooling efficiency is improved, but manufacturing effort increases due to thermal contact requirements
Solution Approach 1:
The cooling channel is merged into the battery cell housing structure itself, eliminating the need for separate cooling plates. This integration removes the manufacturing complexity associated with achieving permanent thermal contact between separate components, as the cooling function is now part of the housing's own structure.
Solution Approach 2:
The housing serves its own cooling needs through the integrated cooling channel, eliminating the need for additional cooling plates that would require precise thermal contact. This self-service approach simplifies manufacturing by removing the requirement for specialized assembly procedures to ensure thermal contact.
3Temperature
If fluid circulation systems are used for cooling, then cooling capacity is improved, but construction cost increases due to fluid-tight connections
Solution Approach 1:
The housing provides its own cooling function through the integrated cooling channel, eliminating the need for external fluid circulation systems and their associated fluid-tight connection requirements. This reduces construction cost by removing complex sealing and connection components.
Solution Approach 2:
The cooling function is merged into the housing structure, eliminating the need for separate fluid circulation systems. This integration removes the construction complexity and cost associated with creating fluid-tight connections between separate cooling components and the battery module.
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
This solution provides effective cooling for battery cells, reducing temperature fluctuations, increasing battery life, and eliminating the need for gap fillers and compression pads, while maintaining high performance and enabling a long range in electric vehicles.
Implementation Method 1
The capillary assembly is in thermal contact with the battery cell so that liquid refrigerant rising from the capillary effect in the capillary assembly is heated by the battery
Implementation Method 2
liquid refrigerant rising from the capillary effect in the capillary assembly is heated by the battery and finally transitions into a gaseous state
Data Source
AI summary
A battery assembly includes at least one battery module having a battery module housing defining a battery module interior, in which at least one battery cell and a refrigerant are arranged. At least one capillary assembly is arranged so as to externally abut against at least one of the at least one battery cells in such a way that it inclines obliquely starting from a first end of the battery cell towards a second end of the battery cell. The capillary assembly is configured so as to receive liquid refrigerant from a refrigerant supply arranged at the first end of the battery cell and release gaseous refrigerant into the battery module interior at least at the second end of the battery cell.