Immersion cooled battery pack for Electric Vehicle safety

Abstract

This battery pack design aims to revolutionize the thermal management of electrical vehicle (EV) batteries through the implementation of an immersion-cooled system. The proposed immersion cooling approach submerges battery cells in a dielectric fluid with excessive thermal conductivity, facilitating speedy and uniform heat dissipation as compared to Conventional cooling methods.

Specification

Description:FIELD OF INVENTION
[001] The invention comes within the field of automotive safety for EV battery system, specifically focusing on the design modifications to increase the safety in electric vehicles. In this design dual battery coolants are used to maintain the battery temperature are safe level.
BACKGROUND AND PRIOR ART
[002] The proposed immersion cooling approach submerges battery cells in a dielectric fluid with excessive thermal conductivity, facilitating speedy and uniform heat dissipation as compared to conventional cooling methods.
[003] EV battery temperature will be maintained in optimal operating conditions.
[004] The proposed battery pack design is unique, it has Die-electric fluids to remove the internal temperature and surface temperature can be reduced by water coolants.
[005] This battery design enhances the safety of the battery pack, preventing short circuits and electrical failures. By maintaining optimal operating temperatures, the immersion-cooling system reduces thermal stress on battery cells, thereby enhancing their efficiency and performance. This results in better energy retention, faster charging times, and increased overall battery lifespan.
SUMMARY OF THE INVENTION
[006] The increasing adoption of electric vehicles (EVs) is a pivotal step towards a sustainable future, reducing greenhouse gas emissions and dependency on fossil fuels. However, one of the critical challenges faced by the EV industry is ensuring the safety, reliability, and efficiency of the battery packs. The occurrence of thermal runaway incidents, which can lead to battery fires and explosions, poses significant risks to both passengers and the broader adoption of EVs.
[007] Traditional cooling methods, such as air cooling and liquid cooling, have limitations in managing the high thermal loads of modern high-capacity battery packs. These methods often result in uneven temperature distribution and inadequate heat dissipation, leading to performance degradation and potential safety hazards.
[008] Immersion-cooling technology, which involves submerging battery cells in a dielectric coolant, presents a promising solution to these challenges. This advanced cooling method ensures uniform temperature distribution, efficient heat dissipation, and enhanced thermal management, significantly reducing the risk of thermal runaway and improving overall battery performance and lifespan.
BRIEF DESCRIPTIONS OF DRAWINGS
[009] Lithium-ion Battery pack (1) has two heat dissipation points, one is water coolant (2) for cooling the top and bottom terminals of the battery. Another coolant point (3) is die-electric coolant where the battery can be immersed.
[010] The coolants (2) and (3) has heat exchanger (4) and (5) to dissipate the battery heat to the environment. A pump system (6) is integrated to circulate the dielectric fluid and coolant through the cooling channels effectively. This pump system ensures a consistent flow rate and distribution of cooling fluids throughout the battery assembly, maximizing thermal efficiency and ensuring uniform cooling across all components.
[011] A baffle plate of random size is fixed inside the battery pack to direct the fluid to Passover in every region of the battery pack. This ensures the coolant is effectively distributed inside the battery pack.
DETAILED DESCRIPTION OF THE INVENTION
[012] The incorporation of water-cooling channels within the hollow cavities of the top and bottom aluminum plates represents an innovative approach to thermal management in the battery assembly. By directing a flow of coolant through these channels, the aim is to dissipate heat generated during battery operation, thereby maintaining optimal operating temperatures and extending the battery's lifespan.
[013] The cooling system is designed to cater to different operational scenarios. During discharge cycles, the dielectric fluid flows through the channels, effectively cooling the battery cells and preventing excessive heat buildup. This proactive cooling mechanism ensures that the battery operates within a safe temperature range, even under high discharge rates, thus safeguarding against thermal stress and degradation.
[014] Conversely, during charging cycles, the terminals of the battery are subjected to cooling by the flow of coolant through dedicated copper channels. This targeted cooling approach helps mitigate the heat generated during the charging process, ensuring that the battery remains thermally stable and minimizing the risk of overheating or thermal runaway.
[015] To facilitate continuous cooling operation, heat exchangers are employed to regulate the temperature of both the dielectric fluid and coolant. These heat exchangers play a pivotal role in dissipating excess heat from the cooling fluids, maintaining their temperature within optimal ranges for efficient heat transfer.
[016] Furthermore, a 2-in-1 pump system is integrated to circulate the dielectric fluid and coolant through the cooling channels effectively. This pump system ensures a consistent flow rate and distribution of cooling fluids throughout the battery assembly, maximizing thermal efficiency and ensuring uniform cooling across all components. , C , Claims:[017] 1. An immersion cooling system within the battery housing, comprising a cooling fluid that immerses the one or more battery cells and a cooling circuit configured to circulate the cooling fluid to remove heat from the battery cells.
[018] 2. A heat exchanger unit positioned within or adjacent to the battery housing, wherein the heat exchanger unit is configured to transfer heat from the cooling fluid to an external cooling medium.
[019] 3. Fluid circulation mechanism connected to the heat exchanger unit to facilitate the movement of the cooling fluid through the heat exchanger unit and enhance heat dissipation.
[020] 4. Control system configured to selectively activate the immersion cooling system, the secondary cooling system, or both, based on the temperature of the battery cells and the cooling requirements.
[021] 5. The battery pack of claim 1, wherein the immersion cooling system includes a pump for circulating the cooling fluid within the chamber and a radiator for expelling heat from the cooling fluid before it re-enters the chamber.
[022] 6. The battery pack of claim 1, wherein the secondary cooling system is configured to operate in a preemptive or complementary mode relative to the immersion cooling system, based on real-time thermal management needs.

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