Battery Module Cooling Layers for Uniform Electrode Temperature
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery systems fail to maintain a constant temperature throughout the battery pack and individual cells, leading to reduced energy density, increased cell impedance, and premature aging due to inefficient thermal management, particularly during high-power operations.
Innovation Solution
A battery module design featuring partial immersion cooling with dielectric liquid directly around the electrodes, utilizing multiple cooling layers and micro channels within a thermally conductive casing, allowing for efficient heat transfer and recirculation, and a thermal management system that independently controls anode and cathode temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling plates or ribbons are used for thermal management, then cooling capacity is improved, but device complexity and space occupation increase
Solution Approach 1:
The patent extracts the cooling function from separate cooling plates or ribbons and integrates it directly into the cell structure through cooling fins that are part of the cell housing. This eliminates the need for separate cooling components and their associated mounting hardware, reducing overall system complexity while maintaining cooling capacity.
Solution Approach 2:
The cooling fins are merged with the cell housing structure, combining the structural support function with the thermal management function. This integration reduces the number of separate components and simplifies the overall system architecture while providing effective cooling.
2Temperature
If cooling plates with thermal paste are used, then thermal contact is improved, but manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The patent eliminates the need for thermal paste by directly integrating cooling fins into the cell housing structure. This removes the application and curing steps for thermal paste from the manufacturing process, significantly simplifying assembly operations and reducing manufacturing complexity.
Solution Approach 2:
The cooling fins act as an integrated intermediary structure that provides both mechanical support and thermal conduction pathways. This eliminates the need for separate thermal interface materials while maintaining effective thermal contact between the cell and cooling system.
3Temperature
If radial cooling with ribbons is used, then cooling capacity is improved, but current imbalance inside cells increases
Solution Approach 1:
Instead of applying cooling radially from the sides (which causes current imbalance), the patent uses axial cooling through fins extending from the cell ends. This inverted cooling approach cools the cell from the electrode terminals, maintaining uniform current distribution while providing effective thermal management.
4Temperature
If cooling plates are used, then thermal management is improved, but energy density decreases
Solution Approach 1:
The cooling fins are merged with the cell housing structure, eliminating the need for separate cooling plates that would occupy additional space. This integration maximizes the use of available volume for energy storage while providing effective thermal management.
Solution Approach 2:
The patent transitions from planar cooling plates to three-dimensional cooling fins that extend axially from the cell ends. This dimensional change provides enhanced cooling surface area without increasing the radial footprint, thereby preserving energy density while improving thermal management.
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 energy and power density, maintains uniform cell temperatures, reduces cell impedance, and extends battery life by efficiently managing heat during high-power operations.
Implementation Method 1
partial immersion cooling means positioned directly around at least one electrode of the cells
Implementation Method 2
one or more cooling layers, such that each cooling layer is configured to contain partial immersion cooling means in such a manner that said partial immersion cooling means are positioned directly around at least one electrode of the cells
Data Source
AI summary
A battery module comprising a plurality of cells and a casing comprising one or more cell-containing layers configured to house the cells is provided. The casing further comprises one or more cooling layers, such that each cooling layer is configured to contain the partial immersion cooling means in such a manner that said partial immersion cooling means are positioned directly around at least one electrode of the cells. A battery pack thermal management system for a vehicle comprising at least one of the battery modules is also provided, as well as a method of controlling the cell temperature of a battery module using said system.