Prismatic Battery Pack with Integral Coolant Channels
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Solution Overview
Problem
High-voltage battery packs face challenges in efficient cooling, particularly in hybrid vehicle applications, due to sub-optimal heat sink placement and temperature degradation of cooling mediums, leading to potential cell damage and limited power output.
Innovation Solution
The integration of integral coolant passages with an intake plenum, exhaust plenum, and distributed U-shaped coolant channels within stackable battery cell modules ensures uniform cooling by forcing air through the channels, which are positioned in thermal proximity to the battery cells, effectively addressing heat distribution issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If external heatsinks are attached to the battery pack, then heat dissipation capability is improved, but space utilization deteriorates and weight increases
Solution Approach 1:
The cooling channels are integrated directly into the battery module housing structure, merging the cooling system with the structural components. This eliminates the need for separate external heatsinks while maintaining effective heat dissipation, thereby improving space utilization without sacrificing thermal management capability
Solution Approach 2:
The battery module housing serves as an intermediary component that simultaneously provides structural support and thermal management functions. By incorporating cooling channels within the housing, the structure acts as both a mechanical enclosure and a heat transfer medium carrier, eliminating the need for additional external cooling components
2Temperature
If external heatsinks are attached to the battery pack, then heat dissipation capability is improved, but weight increases
Solution Approach 1:
The cooling system is merged with the existing battery module housing structure, eliminating the need for separate external heatsinks. This integration removes redundant components and reduces overall system weight while maintaining effective heat dissipation capability through the integrated cooling channels
Solution Approach 2:
The battery module housing is designed to serve multiple functions simultaneously: structural support, mechanical protection, and thermal management. By making the housing multi-functional, the patent eliminates the need for separate dedicated cooling components, thereby reducing weight without compromising heat dissipation performance
3Loss of energy
If metal heat runners are used to transfer heat, then heat transfer efficiency is improved, but distance from terminals to heatsinks becomes a limiting factor
Solution Approach 1:
The cooling channels are positioned in close proximity to the battery cell terminals, which are the primary heat generation points. This local placement ensures that heat is extracted at its source before it can spread or accumulate, maintaining high heat transfer efficiency while minimizing the effective heat transfer distance
Solution Approach 2:
The integrated cooling channels within the housing serve as an intermediary heat transfer path that directly contacts or closely approaches the battery terminals. This intermediary structure provides an efficient thermal coupling between the heat generation points and the coolant flow path, eliminating the need for long-distance heat runners
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 solution provides efficient and uniform cooling of prismatic-cell battery packs, preventing overheating and extending battery life while maintaining low cost and efficient power output.
Implementation Method 1
A coolant medium such as air is forced into the intake plenum, enters the various coolant channels in parallel, draws heat away from the battery cells
Implementation Method 2
each module supports at least one prismatic battery cell in thermal proximity to an array of coolant channels
Data Source
AI summary
A prismatic-cell battery pack is provided with integral coolant passages including an intake plenum, an exhaust plenum, and a distributed array of coolant channels coupled between the intake plenum and the exhaust plenum. Coolant medium forced into the intake plenum enters the coolant channels in parallel, draws heat away from the battery cells, and then enters the exhaust plenum for expulsion into the atmosphere. The battery pack is configured as a set of stackable interlocking battery cell modules including at least one battery cell in thermal proximity to an array of coolant channels distributed over the profile of the battery cell, and a pair of peripheral chambers joined to opposite ends of the coolant channels to form the intake and exhaust plenums when the modules are arranged and interlocked in a lineal stack.