Dielectric Spray Cooling Layout for Fast-Charging Battery Units
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing air cooling systems for battery units are ineffective during high-power charging phases, leading to temperature exceedance and potential safety issues.
Innovation Solution
A dielectric-fluid circulation and spraying system is integrated within the battery unit structure, comprising a circulation circuit, spray means, and extraction means, allowing direct fluid spraying onto cells for efficient cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If air cooling systems are used to cool the battery unit, then the structure is simple and easy to implement, but the cooling effectiveness is insufficient during high-power charging phases
Solution Approach 1:
The patent replaces air cooling with a liquid dielectric fluid cooling system. The circulation circuit pumps dielectric fluid through channels in the receptacle and longitudinal members, and spray means direct the fluid onto the cell faces. This hydraulic approach provides superior heat transfer efficiency compared to air cooling, effectively managing thermal loads during high-power charging while maintaining system reliability.
Solution Approach 2:
The dielectric fluid acts as an intermediary substance between the heat source (battery cells) and the cooling system. The fluid circulates through the circulation circuit, absorbs heat from the cells via conduction through the receptacle bottom and longitudinal members, and transports it to cooling zones. This intermediary mechanism enables effective heat removal while electrically isolating the cooling system from the battery cells.
2Reliability
If dielectric fluid circulation circuit and spray means are integrated into the battery unit structure, then cooling effectiveness is improved, but the device complexity increases
Solution Approach 1:
The patent merges the cooling system components with the battery unit's structural elements. The circulation circuit is integrated into the receptacle bottom and longitudinal members, which also serve as mechanical support structures. The spray means are incorporated into the longitudinal members. This merging approach provides effective cooling while minimizing the addition of separate, discrete components, thereby controlling overall system complexity.
Solution Approach 2:
The receptacle and longitudinal members serve dual functions: they provide mechanical support and structural integrity for the battery cells, while simultaneously housing the dielectric fluid circulation channels and spray means. This multi-functionality reduces the need for dedicated cooling components, simplifying the overall device architecture while maintaining high cooling effectiveness.
3Productivity
If high-power charging is implemented to reduce charging time, then productivity is improved, but temperature control becomes more difficult and safety risks increase
Solution Approach 1:
The dielectric fluid circulation system operates continuously during high-power charging to maintain constant cooling. The circulation pump maintains continuous fluid flow through the receptacle and longitudinal members, ensuring uninterrupted heat removal. The spray means continuously mist the fluid onto the cell faces, providing sustained evaporative cooling. This continuous cooling action enables safe high-power charging by preventing temperature accumulation that would otherwise limit charging speed.
Solution Approach 2:
The system utilizes evaporative phase transition of the dielectric fluid for cooling. The spray means atomize the liquid fluid into fine droplets that evaporate upon contact with the warm cell surfaces, absorbing latent heat of vaporization. This phase change mechanism provides intense cooling effect that can handle the high thermal loads generated during fast charging, enabling high productivity while maintaining temperature control and safety.
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 system effectively maintains cell temperature within safe limits during high-power charging, preventing thermal runaway and reducing bulk impact.
Implementation Method 1
a dielectric-fluid circulation circuit positioned in the bottom of the receptacle and in the thickness of the longitudinal members
Implementation Method 2
spray means for spraying the dielectric fluid onto the rows of cells
Data Source
AI summary
A battery unit includes a plurality of rows of cells, longitudinal members positioned between the rows of cells, a receptacle receiving the plurality of rows of cells and the longitudinal members, and a cooling system for cooling the cells. The cooling system includes:a dielectric-fluid circulation circuit positioned in the bottom of the receptacle and in the thickness of the longitudinal members,spray elements for spraying the dielectric fluid onto the rows of cells, the spray elements passing through an upper surface of the longitudinal members and communicating with the circulation circuit, andan extraction device for extracting the sprayed dielectric fluid passing through the upper surface and opening into the circulation circuit, anda dielectric-fluid cooling circuit connected to the circulation circuit.