Swappable Battery Module Docking for Immersion Cooling Control
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Solution Overview
Problem
Existing battery packs face challenges in efficiently managing the temperature of battery cells and bus bars, particularly in swappable modules, due to limitations in liquid cooling distribution and the need for efficient heat removal during high charge/discharge rates.
Innovation Solution
The development of swappable battery modules featuring immersion-thermally controlled prismatic battery cells, where the cells are directly in contact with thermal fluid at multiple locations, allowing for efficient heat transfer and management. The modules include a dock system with fluidic ports for easy connection and disconnection, enabling fast and efficient thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If liquid cooling is used to manage battery cell temperature, then heat removal efficiency is improved, but the complexity of liquid distribution control worsens
Solution Approach 1:
The patent combines the battery cell container with the liquid cooling system into an integrated unit. The container serves dual functions: housing the battery cells and distributing the liquid coolant. This merging eliminates the need for separate, complex liquid distribution control systems while maintaining effective thermal management.
Solution Approach 2:
The container is designed to perform multiple functions simultaneously: it acts as both the battery cell housing and the liquid cooling distribution system. This multi-functionality reduces overall system complexity by eliminating dedicated liquid distribution components while maintaining effective temperature control.
2Temperature
If cylindrical cells are used for ease of cooling, then thermal management is improved, but energy density worsens due to packing limitations
Solution Approach 1:
The patent segments the battery system into modular units where prismatic cells are arranged in configurations that optimize both thermal management and space utilization. This segmentation allows for efficient liquid distribution across multiple cell surfaces while achieving higher packing density compared to cylindrical cells.
Solution Approach 2:
The patent utilizes three-dimensional liquid distribution pathways that contact multiple surfaces of prismatic cells, effectively using spatial dimensions to enhance cooling efficiency. This approach allows comprehensive thermal management while maintaining high energy density through optimized cell arrangement.
3Device complexity
If bus bars are not cooled, then system complexity is reduced, but overheating of bus bars occurs
Solution Approach 1:
The patent merges the bus bar cooling function with the existing liquid cooling system. The same liquid distribution network that cools the battery cells also provides cooling to the bus bars, eliminating the need for separate cooling systems while preventing bus bar overheating.
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 effective temperature control for battery cells and bus bars, enhancing the operational efficiency and safety of battery packs by maintaining optimal temperatures during charging and discharging, even at high rates.
Implementation Method 1
the cells are directly in contact with thermal fluid at multiple locations, allowing for efficient heat transfer and management
Implementation Method 2
Joule heating caused by cells' internal resistance is one of the largest contributors
Data Source
AI summary
Described herein are swappable battery modules comprising immersion-thermally controlled prismatic battery cells and methods of operating thereof. A method comprises positioning a swappable battery module on a battery dock comprising dock fluidic ports and sliding the swappable battery module to the dock fluidic ports until these dock's ports are fluidically coupled with the module's fluidic ports. Specifically, the dock comprises an enclosure and a module support rail slidably coupling the swappable battery module and the enclosure. The module support rail comprises a rail base, a first slider, a second slider, and a lever-based unit, interconnecting the rail base and both sliders. The rail base is fixed to the enclosure, while the second slider is detachably coupled to the module. The two sliders move at different speeds or at the same speed relative to the dock base depending on the proximity of the first end plate to the dock base.