Honeycomb Battery Pack Cooling for Fast Heating and High Energy Density
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Solution Overview
Problem
Existing liquid-cooled battery systems face issues of low energy density, low-temperature heating difficulty, and long-term immersion damage, leading to decreased battery life and inefficient thermal management.
Innovation Solution
A honeycomb-immersed heating and cooling integrated battery system with a honeycomb structure and vertical flow channels, utilizing a coolant circulation component and heating film to enhance thermal management, reduce coolant volume, and prevent direct contact with battery cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional immersion cooling is used, then cooling efficiency is improved, but energy density decreases due to increased weight and volume
Solution Approach 1:
The battery pack is divided into multiple independent honeycomb cells, each containing a battery module. This segmentation allows the cooling system to be integrated into the structural framework itself, eliminating the need for separate cooling plates and reducing overall system weight and volume, thereby improving energy density while maintaining cooling efficiency.
Solution Approach 2:
The honeycomb structure serves multiple functions simultaneously: it provides structural support for the battery pack, acts as the cooling system framework, and enables thermal management through integrated coolant flow channels. This multi-functionality eliminates redundant components, reducing system weight and volume while improving energy density.
2Stability of the object's composition
If immersion cooling is used, then thermal uniformity is improved, but battery life decreases due to erosion from long-term liquid contact
Solution Approach 1:
A hydrophobic coating is applied to the honeycomb structure surfaces that contact the battery modules. This coating acts as an intermediary layer that prevents direct chemical contact between the cooling liquid and battery components, eliminating erosion and extending battery life while maintaining the thermal uniformity benefits of immersion cooling.
3Productivity
If traditional liquid cooling plates are used, then cooling capacity is improved, but heating rate at low temperatures decreases
Solution Approach 1:
The system uses electric heating elements integrated into the honeycomb structure that can dynamically switch between heating and cooling modes. During low-temperature conditions, the heating elements rapidly heat the coolant, which then quickly transfers heat to the battery through the honeycomb structure, achieving fast heating rates. During normal operation, the same structure provides efficient cooling, thus dynamically adapting to different thermal management needs.
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 improves energy density, enhances heating and cooling efficiency, and ensures high mechanical strength and safety by minimizing coolant contact, thereby extending battery life and improving thermal uniformity and safety.
Implementation Method 1
a coolant circulation component is used to pump the coolant in the lower chamber to the upper chamber
Implementation Method 2
The cell is attached to a heating film
Data Source
AI summary
A honeycomb-immersed heating and cooling integrated battery system includes a box with a top cover, multiple matrix arranged cells, a honeycomb structure, an upper cover plate, a lower cover plate and a coolant circulation component, where the honeycomb structure has multiple hexagonal close-packed special-shaped cylindrical chambers, each cylindrical chamber contains a cell, the upper cover plate and the lower cover plate are placed on the upper and lower surfaces of the honeycomb structure, respectively, the upper cover plate and the lower cover plate are provided with dense through-holes, the upper chamber is formed between the upper cover plate and the top cover, the lower chamber is formed between the lower cover plate and the bottom of the box, and the coolant circulation component is used to pump the coolant in the lower chamber to the upper chamber.