Electrochemical Cell Case With Integrated Cooling Ducts
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Solution Overview
Problem
Rapid charging of lithium-ion batteries for electric and hybrid vehicles poses challenges due to high currents causing significant heating at electrical connectors, which requires effective cooling to prevent temperature increases and maintain energy density, but existing solutions like dielectric fluid cooling systems are inefficient and prone to leaks.
Innovation Solution
A case for electrochemical cells with integrated ducts for cooling fluid circulation, where the ducts are formed by molding and heat-sealing, allowing dielectric fluid to directly cool electrical connectors, reducing material costs and eliminating the need for additional cooling elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a dielectric fluid cooling system is implemented with dedicated circuits, then cooling effectiveness is improved, but device complexity and risk of leaks increase
Solution Approach 1:
The cooling duct is merged with the cell case structure itself, eliminating the need for separate dedicated cooling circuits. The case walls form the duct boundaries directly, integrating the cooling function into the existing structural component rather than adding a separate system.
Solution Approach 2:
The cell case serves multiple functions: it provides structural containment for the active element and simultaneously forms the cooling duct structure. This multi-functionality reduces overall system complexity by combining structural and thermal management roles in one component.
2Temperature
If internal cooling plates are added to each cell, then cooling capability is improved, but energy density is reduced due to additional materials
Solution Approach 1:
The cooling duct is formed by shaping the existing case walls rather than adding separate cooling plates. The same material that forms the case structure also forms the cooling duct boundaries, eliminating additional materials and preserving energy density.
Solution Approach 2:
The case structure performs dual functions as both the protective enclosure and the cooling duct formation, eliminating the need for separate cooling plates and their associated materials that would reduce energy density.
3Device complexity
If cooling is implemented away from electrical connectors, then structural simplicity is maintained, but cooling effectiveness at heat sources is reduced
Solution Approach 1:
The cooling duct is positioned and shaped to provide localized cooling directly at the electrical connectors where heat generation is most intense. The duct geometry is optimized to concentrate cooling fluid flow at these critical hot spots rather than distributing cooling uniformly throughout the cell.
4Temperature
If multiple connectors per cell are used for cooling, then cooling coverage is improved, but risk of leaks increases
Solution Approach 1:
Multiple connectors are integrated into a single continuous cooling duct structure within the case, rather than having separate connectors requiring multiple sealing points. This reduces the number of potential leak locations while maintaining comprehensive cooling coverage.
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 optimizes cooling by directly addressing heating at electrical connectors, reduces material costs, and minimizes the risk of leaks, enhancing the efficiency and reliability of battery charging while maintaining energy density.
Implementation Method 1
a case for accommodating at least one active element of an electrochemical cell for a battery, the case forming at least one duct intended for the circulation of a cooling fluid, the duct being arranged so as to be passed through by at least one electrical connector of the electrochemical cell
Data Source
AI summary
A case accommodates at least one active element of an electrochemical cell. The case includes at least one duct that receives a circulation of a cooling fluid. The duct is arranged so as to be passed through by at least one electrical connector of the electrochemical cell.