Fluid-Cooled Battery Module With Segmented Thermal Management
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Solution Overview
Problem
Existing battery modules face inefficiencies in thermal management, particularly with air cooling systems that have low thermal conductivity and capacity, leading to inadequate heat removal and uneven temperature distribution across battery cells, which can affect charging efficiency and lifespan.
Innovation Solution
A battery module design featuring a cooling conduit system where chilled coolant is initially directed to the hottest areas, typically the electrical terminals, to maximize heat transfer and then distributed throughout the module, ensuring a more uniform temperature distribution using thermally conductive materials and a case that provides mechanical support and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If air cooling systems are used due to convenience, then ease of operation is improved, but heat removal efficiency deteriorates because air has low thermal conductivity and low heat capacity
Solution Approach 1:
The patent transitions from air cooling to liquid cooling by introducing a cooling fluid (aqueous solution) that flows through channels in thermal contact with battery cells. The liquid coolant provides superior heat capacity and thermal conductivity compared to air, enabling efficient heat removal while maintaining system simplicity through integrated cooling plates
Solution Approach 2:
The patent introduces cooling plates as intermediary components that facilitate heat transfer from battery cells to the cooling fluid. These plates serve as thermal mediators with high conductivity materials, creating an efficient heat transfer pathway that overcomes the limitations of direct air cooling
2Loss of energy
If aqueous cooling fluids are used to improve heat removal efficiency, then heat transfer capability is improved, but reliability deteriorates due to potential leaks and short circuits
Solution Approach 1:
The cooling plates serve multiple functions simultaneously: they provide thermal management through fluid channels, offer mechanical support and structural integrity, and act as protective barriers between the cooling fluid and battery cells. This multi-functionality reduces the need for separate protective components and minimizes leak risks
Solution Approach 2:
The patent incorporates redundant sealing mechanisms and protective design features in the cooling plates and fluid channels to prevent leaks before they occur. The system includes sealed joints, gaskets, and structural designs that cushion against potential failure modes, ensuring reliability even under thermal and mechanical stress
3Device complexity
If conventional cooling systems are used, then device complexity is reduced, but temperature uniformity deteriorates leading to localized overheating in different parts of battery cells
Solution Approach 1:
The patent divides the cooling system into multiple segmented channels and cooling zones that correspond to different regions of the battery module. This segmentation allows targeted cooling of specific hot spots while maintaining overall system simplicity through modular plate designs that can be configured for different battery arrangements
Solution Approach 2:
The cooling plates are designed with varying thermal conductivity regions, channel densities, and flow rates to provide localized cooling where needed. Areas with higher heat generation receive enhanced cooling capacity, while cooler regions receive proportionally less, achieving uniform temperature distribution across the entire battery module
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 approach enhances heat transfer efficiency, maintains a more uniform temperature across the battery module, prolongs operational lifespan, and accommodates varying temperature differentials within larger battery cells, improving overall performance and longevity.
Implementation Method 1
the conduit is in thermal contact with the battery cells to cool them
Implementation Method 2
a cooling conduit having an inlet for receiving chilled coolant... in thermal contact with said cells
Data Source
AI summary
A battery module for receiving battery cells provides cooling through a cooling fluid. Chilled fluid travels first to the hottest part of the battery module and then continues to gradually less hot areas. As the chilled cooling fluid absorbs heat and travels to cooler parts of the battery module, the heat transfer between the fluid and the battery cells decreases because the temperature differential between the cells and cooling fluid decreases, providing a more even temperature distribution across the battery module. The cooling fluid may be contained in a conduit associated with one or more cooling plates. A plurality of slots provide a precise mechanical support for each battery cell, increasing the heat conduction from the cell to the battery module, protecting the battery module from vibration and decreasing contamination in case of thermal runaway or other damage to the cells.