Stacked Separator Plates for Uniform Battery Immersion Cooling

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current thermal management systems for battery assemblies in electric vehicles struggle to efficiently regulate operating temperatures, particularly during fast charging and high-demand conditions, which can lead to thermal runaway.

Innovation Solution

The implementation of thermal management systems using coolant flow distribution plates for liquid immersion cooling (LIC) of battery cells, where separator plates with perforated channels are stacked between cell rows to enhance coolant flow and distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If traditional thermal management systems are used for battery assemblies, then the system structure is simple, but the thermal performance is insufficient and temperature uniformity is poor

Engineering Contradiction:

Improvetemperature uniformityVSAvoidsystem structure

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The separator plate is divided into multiple regions with different channel densities. The front region has a first channel density while the rear region has a second channel density, allowing differential coolant distribution to achieve better temperature uniformity across the battery assembly

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the separator plate are designed with locally optimized channel densities. The front region uses a lower channel density while the rear region uses a higher channel density, matching the local thermal requirements of different battery cell regions

Inventive Principle:

Principle #3Local quality

2Area of stationary object

If coolant flow distribution channels are added to separator plates, then the wetted surface area increases and thermal performance improves, but the device complexity increases

Engineering Contradiction:

Improvewetted surface areaVSAvoidseparator plate structure

Core Design Contradiction:

Area of stationary objectVSDevice complexity

Solution Approach 1:

The separator plate serves dual functions: it maintains electrical isolation between battery terminals and simultaneously distributes coolant flow through integrated channels. This eliminates the need for separate cooling components, reducing overall system complexity while increasing wetted surface area

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If multiple channel bands are stacked between cell rows, then coolant distribution is enhanced and thermal runaway risk is reduced, but manufacturing complexity increases

Engineering Contradiction:

Improvethermal runaway preventionVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The cooling system is segmented into multiple channel bands stacked between cell rows, with each band having optimized channel density for its specific location. This segmentation allows targeted thermal management while maintaining manufacturing feasibility through modular assembly

Inventive Principle:

Principle #1Segmentation

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 improves thermal performance by increasing the wetted surface area of the coolant and enhancing temperature uniformity across battery cells, thereby reducing the risk of thermal runaway and increasing battery life and vehicle efficiency.

Implementation Method 1

coolant channels cooperatively distribute coolant fluid onto and vertically upward between the battery cells

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 2

direct-conduction dielectric liquid coolant

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

direct-conduction dielectric liquid coolant

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 4

liquid immersion cooling (LIC)

Methodology Applied

Scientific EffectCooling: Cooling

Data Source

PatentUS12322779B2Stacked separator plates with coolant flow distribution channels for liquid immersion cooling in battery assemblies

Publication Date: 2025.06.03 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

Presented are thermal management systems using coolant flow distribution plates for immersion cooling of battery cells, methods for making/using such systems, and vehicles equipped with such systems for cooling the vehicles' battery packs. A battery assembly includes multiple battery cells arranged in adjacent, mutually parallel cell rows. The battery cells are stored inside a protective battery housing that includes inlet and outlet fluid ports for receiving and evacuating therethrough dielectric coolant fluid. A pair of (first and second) separator plates is located between each neighboring pair of cell rows. Each plate includes coolant channels that are arranged in mutually parallel channel bands. The separator plates are in face-to-face contact with each other such that each channel band of the first separator plate is aligned with a respective channel band of the second plate so the coolant channels cooperatively distribute coolant fluid onto and vertically upward between the battery cells.