Dielectric Fluid Battery Pack Cooling for Dense Cylindrical Cell Modules
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Solution Overview
Problem
Conventional battery modules with cylindrical cells face challenges in packing efficiency and cell cooling due to their curved shape and the complexity of cell support structures, which complicates space management and cooling within the module.
Innovation Solution
A battery pack design featuring a dielectric fluid-filled housing with a thermal management system that includes an inlet and outlet plenum assembly and fluid pump, along with bus bar assemblies for efficient cell interconnections, to provide both passive and active cooling while minimizing space and simplifying manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cylindrical cells are used in battery modules, then ease of manufacturability and stability are improved, but packing efficiency deteriorates due to curved shape
Solution Approach 1:
The battery module is divided into multiple cell stacks, with each stack containing a specific number of cylindrical cells arranged in a structured configuration. This segmentation allows efficient space utilization while maintaining the manufacturing advantages of cylindrical cells.
Solution Approach 2:
The patent transitions from traditional single-layer cell arrangement to a three-dimensional stacked configuration. Multiple layers of cylindrical cells are vertically arranged and secured by end plates, maximizing the use of available space within the battery module housing.
2Stability of the object's composition
If cell support structures are provided to retain cells and provide cooling, then cell stability is improved, but device complexity increases
Solution Approach 1:
The support structure is merged with the cooling system by integrating coolant flow channels directly into the end plates and cell retention mechanisms. This combination eliminates the need for separate support and cooling components, reducing overall device complexity while maintaining cell stability and thermal management.
3Temperature
If cell support structures are provided with sufficient bulk to provide cooling, then cell cooling is improved, but packing efficiency deteriorates
Solution Approach 1:
The cooling system utilizes hydraulic channels formed within the end plates, allowing coolant to flow directly through the support structures. This approach provides effective cell cooling while minimizing the volume occupied by cooling components, as the cooling function is integrated into the existing structural elements rather than adding separate bulk components.
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 design enhances packing efficiency, improves cell durability, and allows for individual temperature control of each battery module, balancing the overall pack temperature while reducing manufacturing complexity.
Implementation Method 1
The battery pack housing is filled with a first fluid that is dielectric... terminals of the cells are exposed to fluid disposed in the fluid passageway
Implementation Method 2
a thermal management system that circulates the first fluid through the module housings of each battery module... a fluid pump that directs fluid to the inlet plenum assembly via a fluid delivery line and receives fluid from the outlet plenum assembly via a fluid return line
Implementation Method 3
The battery pack housing is filled with a first fluid that is dielectric... terminals of the cells are exposed to fluid disposed in the fluid passageway
Data Source
AI summary
A battery pack including a battery pack housing, and a battery module disposed in the battery pack housing, Tire pack housing is sealed and flooded with a dielectric fluid. The battery module includes a module housing that is fluid permeable and includes a fluid passageway, and electrochemical cells disposed in the module housing in such a way that terminals of the cells are exposed to fluid disposed in the fluid passageway. The battery pack includes a thermal management system having an inlet plenum assembly disposed at a first end of the battery module, an outlet plenum assembly disposed at a second end of the battery module, and a fluid pump that directs fluid to the inlet plenum assembly via a fluid delivery line and receives fluid from the outlet plenum assembly via a fluid return line.