Immersion-Cooled Prismatic Battery Module With Bus Bar Cooling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery modules face challenges in efficiently managing temperature control, particularly for prismatic cells, due to limited thermal coupling and cooling of bus bars, leading to reduced energy density and potential safety risks.
Innovation Solution
The implementation of immersion-cooled prismatic battery cells within a battery module design, where cells are directly contacted by thermal liquid through fluid channels formed by top and bottom covers, with bus bars also immersed for direct cooling, and end plates managing fluid distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If liquid cooling is implemented with thermal liquid passages, then heat dissipation is improved, but device complexity increases due to isolated cells from direct liquid contact
Solution Approach 1:
The patent removes the intermediate thermal management components that traditionally isolate battery cells from direct liquid contact. By extracting these intermediary elements, the system achieves direct immersion cooling where thermal liquid flows immediately around battery cells and bus bars, simplifying the cooling system structure while maintaining effective heat dissipation.
2Temperature
If cylindrical cells are used for ease of cooling, then heat dissipation is improved, but energy density decreases due to packing limitations
Solution Approach 1:
The patent changes the geometric parameter of battery cells from cylindrical to prismatic shape. This parameter change enables better packing density within the battery module while simultaneously allowing direct immersion cooling of the cell surfaces, thus achieving both high energy density and effective heat dissipation.
3Temperature
If battery cells are cooled but bus bars are not, then battery temperature is controlled, but overall thermal management is insufficient leading to safety risks
Solution Approach 1:
The patent implements a universal thermal management approach where the same immersion cooling system cools both battery cells and bus bars simultaneously. The thermal liquid flows through passages that contact both components, providing comprehensive temperature control across all heat-generating elements within the battery module, thereby improving overall safety and reliability.
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 dissipation, maintains uniform temperature profiles, increases energy density, and improves safety by reducing the size and weight of the module while ensuring efficient thermal management.
Implementation Method 1
liquid cooling or, more generally, liquid-based thermal management of battery cells is beneficial in comparison to, e.g., air cooling because of the large heat capacities and heat transfer coefficient of many liquids in comparison to air
Implementation Method 2
Joule heating caused by cells' internal resistance is one of the largest contributors
Data Source
AI summary
Described herein are battery modules comprising immersion-cooled prismatic battery cells and methods of fabricating thereof. A battery module comprises prismatic battery cells that are stacked along the primary module axis. The module also comprises top, bottom, and side covers and two end plates, collectively enclosing these battery cells. Each cover forms two fluid channels, both fluidically open to the prismatic battery cells. Furthermore, the module comprises bus bars that interconnect the cell terminals and protrude into the fluid channels formed by the top cover. One end plate comprises two fluid ports for connecting to a thermal management system. Each port is fluidically coupled to one fluid channel, formed by the top cover, and one fluid channel, formed by the bottom cover. The other end plate fluidically couples the two fluid channels, formed by the top cover, and, separately, the two fluid channels, formed by the bottom cover.