Swappable Prismatic Battery Module With Immersion Cooling Channels
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Solution Overview
Problem
Existing battery modules face challenges in efficiently managing temperature control, particularly for swappable prismatic cells, due to difficulties in thermal coupling and fluid distribution, which can lead to overheating and reduced energy density.
Innovation Solution
The implementation of immersion-thermally controlled prismatic battery cells within a tubular enclosure, with fluid channels on multiple surfaces for direct thermal contact and circulation, along with adhesive layers for structural integrity and electrical isolation, allowing for efficient thermal management and higher energy density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If liquid cooling is used with direct thermal contact, then heat transfer efficiency is improved, but controlling fluid distribution and preventing overheating becomes more challenging
Solution Approach 1:
The battery module is divided into multiple cell stacks, each with its own fluid channels formed by tubular enclosures. This segmentation allows independent thermal management of each stack, improving heat transfer efficiency while maintaining manageable fluid distribution control through modular design.
Solution Approach 2:
Tubular enclosures serve as intermediary components that form fluid channels between the cooling fluid and battery cells. These enclosures enable direct thermal contact while providing a controlled interface for fluid distribution, resolving the contradiction between efficient heat transfer and fluid control complexity.
2Ease of operation
If cylindrical cells are used for ease of cooling, then thermal management is simplified, but energy density decreases due to packing limitations
Solution Approach 1:
Instead of using cylindrical cells for ease of cooling, the patent inverts the approach by using prismatic cells with specially designed tubular enclosures that form fluid channels. This inversion maintains ease of thermal management through direct fluid contact while achieving superior energy density through better packing efficiency of prismatic geometry.
Solution Approach 2:
The patent introduces fluid channels in multiple dimensions around the prismatic cells rather than relying on single-point cooling. Tubular enclosures create three-dimensional fluid pathways that provide efficient thermal management while allowing dense packing of prismatic cells, resolving the contradiction between ease of cooling and energy density.
3Weight of moving object
If bus bars are made with smaller cross-sections to reduce weight, then weight is reduced, but overheating risk increases
Solution Approach 1:
Fluid channels formed by tubular enclosures act as intermediary cooling pathways that directly contact the bus bars. This allows the use of smaller, lighter bus bar cross-sections while preventing overheating through efficient direct cooling, resolving the contradiction between weight reduction and temperature control.
4Quantity of substance
If prismatic cells are used for higher energy density, then packing efficiency is improved, but thermal coupling and fluid distribution become more difficult
Solution Approach 1:
The tubular enclosures serve multiple functions: they provide structural support for prismatic cells, form fluid channels for thermal management, and enable direct thermal contact. This multi-functionality allows prismatic cells to achieve high energy density while simplifying thermal coupling through a single integrated component.
Solution Approach 2:
The patent creates three-dimensional fluid channels around the prismatic cells using tubular enclosures, enabling efficient thermal coupling in multiple dimensions. This resolves the contradiction between high energy density from prismatic packing and thermal management complexity by providing omnidirectional heat dissipation pathways.
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 design ensures uniform temperature distribution and higher energy density by direct thermal contact, enabling safe operation at high charge/discharge rates and reducing the weight and size of external components.
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
immersion-thermally controlled prismatic battery cells... direct thermal contact
Implementation Method 3
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 module comprises a tubular enclosure attached (e.g., glued) to different surfaces of the cells and forming two fluid channels with one side of the cells and two additional fluid channels with the opposite side. The module also comprises a first end plate, which is attached to the tubular enclosure and comprises two electrical terminals for connecting to an electric vehicle (EV) and/or external charger. The first end plate also comprises a first fluidic port (fluidically coupled with two fluid channels) and a second fluidic port (fluidically coupled to the remaining two fluid channels), both are configured to form fluidic coupling to the electric vehicle and/or the external charger. The module also comprises a second end plate that fluidically interconnects paid fluid channels from different cell sides.