Immersion Cooled Battery Module with Integrated Interfaces
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Solution Overview
Problem
Conventional modular cooled battery packs face challenges due to increased material costs, complex manufacturing processes, and reliability issues, and are not adaptable to various vehicle platforms and application specifications.
Innovation Solution
An immersion cooled battery module design featuring a battery enclosure with flow control members and sealing members to manage fluid flow between cell assemblies, allowing for easy assembly and adaptability to different applications, reducing the need for additional connectors and simplifying manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a modular cooled battery pack is used, then the battery pack can be adapted to various vehicle platforms and sizes, but the number of connectors (electrical, mechanical, and liquid) increases, leading to higher material costs, complex manufacturing processes, and potential reliability issues
Solution Approach 1:
The patent combines multiple connector functions into a single integrated enclosure interface structure. The enclosure interface includes both mechanical support functions and electrical connection functions (through assembly electrodes), eliminating the need for separate mechanical connectors and electrical connectors. This merging reduces the total number of connectors while maintaining modular adaptability to different vehicle platforms.
Solution Approach 2:
The enclosure interface is designed as a universal multi-functional component that serves multiple purposes: structural support, electrical connection, and fluid sealing. The assembly electrodes provide both mechanical attachment and electrical connectivity, while the integrated design allows the same interface structure to work across different battery module configurations and vehicle platforms, reducing the need for platform-specific connector variations.
2Ease of manufacture
If each cell assembly is enclosed in an independent liquid container (modular design), then the battery pack becomes modularized, but more connectors are required between modules
Solution Approach 1:
The patent merges the liquid container function with the enclosure interface structure. The same enclosure that provides structural housing for the cell assembly also serves as the fluid container and includes the electrical connection interfaces. This eliminates separate liquid connectors and electrical connectors, reducing the number of potential failure points while maintaining modular assembly benefits.
Solution Approach 2:
The patent converts the potential harm of having multiple connectors into a benefit by integrating them into a single robust enclosure interface. The assembly electrodes, which would normally be separate electrical connectors, are integrated into the enclosure structure itself, making the connection more reliable and reducing the number of potential failure points.
3Device complexity
If a non-modular cooled battery pack with one large liquid tank is used, then the structure is simpler, but the pack becomes bulky and heavy, making it difficult to employ on various sizes of vehicle platforms
Solution Approach 1:
The patent segments the large liquid tank into multiple smaller independent fluid containers, each associated with a specific cell assembly or group of cell assemblies. This segmentation allows the battery pack to be divided into modular units that can be configured in different arrangements to fit various vehicle platforms and size requirements, while maintaining the simplicity of the liquid cooling structure within each module.
Solution Approach 2:
The patent transitions from a single large three-dimensional liquid tank to multiple smaller fluid containers distributed throughout the battery module array. This dimensional redistribution allows for flexible packaging and configuration that adapts to different vehicle platform constraints while maintaining effective cooling coverage.
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 solution enhances manufacturing efficiency, reduces material costs, and improves reliability by allowing for modular assembly and adaptability to various vehicle platforms and specifications, while effectively managing heat through fluid flow control.
Implementation Method 1
manage the heat generated during the charging and discharging processes
Implementation Method 2
fluid to flow into the battery enclosure... fluid to flow out of the battery enclosure
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
A battery module is provided. The battery module includes a battery enclosure and a plurality of cell assemblies. The battery enclosure includes a front plate, a fluid inlet, a fluid outlet, and a plurality of enclosure interfaces. The fluid inlet is disposed on the front plate for a fluid to flow into the battery enclosure. The fluid outlet is disposed on the front plate for the fluid to flow out of the battery enclosure. The plurality of enclosure interfaces is disposed on the front plate. Each of the plurality of cell assemblies has a plurality of assembly electrodes and is installed in the battery enclosure. Each of the plurality of assembly electrodes is respectively coupled to one of the plurality of enclosure interfaces and electrically exposed to an outside of the front plate.