Dielectric Spray Cooling Layout for Dense Battery Cell Rows
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Solution Overview
Problem
Existing battery thermal management systems for electric vehicles face challenges such as non-homogeneous cooling, high thermal resistance, and increased cost and weight due to the use of dielectric fluids, as well as spatial inefficiencies in dielectric fluid circuits that reduce the number of cells that can be packed in a given volume.
Innovation Solution
A battery design featuring rows of energy storage cells with a dielectric fluid circuit that includes spray orifices positioned flush with the upper side or laterally offset, allowing for efficient cooling while minimizing the height requirement and avoiding interference with electrical connectors, using a closed loop system with a condensation plate and pump to manage the dielectric fluid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cells are immersed in dielectric fluid for cooling, then thermal management performance is improved, but the quantity of dielectric liquid increases leading to higher cost and weight
Solution Approach 1:
The patent applies local quality by transitioning from global immersion cooling to localized spray cooling. Instead of filling the entire battery enclosure with dielectric fluid, spray nozzles are positioned at specific locations (upper side and/or lateral sides of cell rows) to deliver cooling only where heat generation occurs. This localized approach maintains effective thermal management while dramatically reducing the total quantity of dielectric liquid required.
Solution Approach 2:
The invention extracts the dielectric fluid from the bulk immersion configuration and delivers it through controlled spray nozzles. By taking out the fluid from a static immersion state and delivering it dynamically through spray outlets, the system achieves efficient cooling with minimal fluid quantity, directly addressing the contradiction between cooling performance and fluid quantity.
2Quantity of substance
If dielectric fluid circuits are configured for spraying cells, then dielectric fluid quantity is reduced, but spatial requirements increase particularly in height direction
Solution Approach 1:
The patent resolves the spatial contradiction by transitioning the circuit configuration from a vertical arrangement (requiring height space) to a lateral arrangement. Spray nozzles are positioned on lateral sides of cell rows and directed horizontally toward the cells, eliminating the need for vertical clearance. This dimensional change allows the circuit to be integrated within the battery pack's horizontal footprint without increasing height requirements.
Solution Approach 2:
Instead of positioning spray nozzles above the cells and directing fluid downward (which would require height space), the invention inverts the approach by positioning nozzles on lateral sides and directing fluid horizontally. This inverted configuration achieves the same cooling function while eliminating the height penalty associated with traditional overhead spray systems.
3Temperature
If spray circuit elements are positioned between cells, then cooling is effective, but cell density is reduced at given volume
Solution Approach 1:
The patent applies nesting by integrating the spray circuit elements within the existing battery pack structure rather than adding them as separate external components. The spray nozzles are positioned on lateral sides of cell rows, utilizing the inter-row spaces already present in the battery architecture. This nested integration allows the cooling circuit to coexist with the cell arrangement without reducing cell density or requiring additional volume.
4Temperature
If circuit elements are positioned close to upper cell faces, then cooling efficiency is maintained, but electrical connection connectors may interfere with dielectric fluid circuit
Solution Approach 1:
The patent applies asymmetry by positioning spray nozzles on lateral sides of cell rows rather than symmetrically above the cells. This asymmetric lateral positioning directs the spray trajectory horizontally along the cell sides, creating a spatial separation between the dielectric fluid path and the electrical connection connectors located on the upper faces. This asymmetric configuration eliminates interference while maintaining cooling efficiency through direct lateral impingement on the cell surfaces.
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 achieves efficient cooling of battery cells with reduced dielectric fluid usage, minimizing the battery's height and weight while maintaining high cell density and performance, thereby enhancing the thermal management and cost-effectiveness of the battery pack.
Implementation Method 1
a dielectric fluid circuit, said circuit comprising one or more spray orifice(s) for said cells
Implementation Method 2
direct contact established between the liquid and the cells
Implementation Method 3
said battery comprises a condensation plate, located facing said upper face of the cells
Data Source
AI summary
A battery includes at least one row of energy storage cells. The row of energy storage cells has a longitudinal extension direction with an upper side and lateral sides being respectively defined by a series of upper and lateral faces of the energy storage cells and of spaces separating the energy storage cells in the longitudinal extension direction. The battery also includes a dielectric fluid circuit with one or more spray orifices. The spray orifices are flush with the upper side of the row of energy storage cells and are located facing a lateral side of the row such that the dielectric fluid circuit leaves the upper side of the row free.