WO2023170661A1 - System and method for battery thermal management - Google Patents

System and method for battery thermal management Download PDF

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Publication number
WO2023170661A1
WO2023170661A1 PCT/IB2023/052348 IB2023052348W WO2023170661A1 WO 2023170661 A1 WO2023170661 A1 WO 2023170661A1 IB 2023052348 W IB2023052348 W IB 2023052348W WO 2023170661 A1 WO2023170661 A1 WO 2023170661A1
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WO
WIPO (PCT)
Prior art keywords
heat transfer
batteries
transfer fluid
battery
battery case
Prior art date
Application number
PCT/IB2023/052348
Other languages
French (fr)
Inventor
Ashay Ghogare
Om Prakash Rathod
Original Assignee
Speedloop Auto Private Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Speedloop Auto Private Limited filed Critical Speedloop Auto Private Limited
Publication of WO2023170661A1 publication Critical patent/WO2023170661A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L50/00—Electric propulsion with power supplied within the vehicle
    • B60L50/50—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells
    • B60L50/60—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells using power supplied by batteries
    • B60L50/64—Constructional details of batteries specially adapted for electric vehicles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L3/00—Electric devices on electrically-propelled vehicles for safety purposes; Monitoring operating variables, e.g. speed, deceleration or energy consumption
    • B60L3/0023—Detecting, eliminating, remedying or compensating for drive train abnormalities, e.g. failures within the drive train
    • B60L3/0046—Detecting, eliminating, remedying or compensating for drive train abnormalities, e.g. failures within the drive train relating to electric energy storage systems, e.g. batteries or capacitors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L58/00—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles
    • B60L58/10—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles for monitoring or controlling batteries
    • B60L58/24—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles for monitoring or controlling batteries for controlling the temperature of batteries
    • B60L58/26—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles for monitoring or controlling batteries for controlling the temperature of batteries by cooling
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/425—Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/42—Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells
    • H01M10/48—Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte
    • H01M10/486—Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte for measuring temperature
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/61—Types of temperature control
    • H01M10/613—Cooling or keeping cold
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/63—Control systems
    • H01M10/633—Control systems characterised by algorithms, flow charts, software details or the like
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/65—Means for temperature control structurally associated with the cells
    • H01M10/655—Solid structures for heat exchange or heat conduction
    • H01M10/6556—Solid parts with flow channel passages or pipes for heat exchange
    • H01M10/6557—Solid parts with flow channel passages or pipes for heat exchange arranged between the cells
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M10/00—Secondary cells; Manufacture thereof
    • H01M10/60—Heating or cooling; Temperature control
    • H01M10/65—Means for temperature control structurally associated with the cells
    • H01M10/656—Means for temperature control structurally associated with the cells characterised by the type of heat-exchange fluid
    • H01M10/6567—Liquids
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L2240/00—Control parameters of input or output; Target parameters
    • B60L2240/40—Drive Train control parameters
    • B60L2240/54—Drive Train control parameters related to batteries
    • B60L2240/545—Temperature
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries

Definitions

  • the present disclosure is related to a system and method for thermal management of batteries.
  • the present disclosure relates to a system and method for active (or passive) thermal management of batteries wherein the thermal management includes submerging one or more cells or batteries inside the heat transfer fluid.
  • Conventional cooling systems for cooling batteries employ coolant fluids passing through pipes, tubes, or other channels where some portions of the individual battery cells are in contact with the fluid channel or have a path to reject heat to the channel, either through contact with a thermally conductive component (e.g., a heat sink) or through direct contact with other battery cells.
  • Conventional methods typically suffer from the limitations of limited contact area with individual battery cells and poor thermal conduction across the contact area. Furthermore, these methods have several components through which heat from the batteries must travel to reach the ultimate cooling fluid, thereby resulting in the limited ability to effectively remove heat.
  • these measures introduce significant additional mass and volume to the battery pack that reduce the volume, weight, and effectiveness of the battery pack while increasing cost.
  • conventional battery thermal management systems provide limited or no significant protection from thermal runaway events.
  • An object of the present disclosure is to provide a system and method for thermal management of batteries.
  • Another object of the present disclosure is to provide an apparatus for thermal management of batteries.
  • Another object of the present disclosure is to provide a method for thermal management of batteries.
  • Yet another object of the present disclosure is to provide a system for providing protection to battery-cells from thermal runaway.
  • embodiments of the present disclosure provide a system for battery thermal management, wherein the system comprises: one or more battery case; one or more batteries configured to be at least partially submerged within a heat transfer fluid contained in the one or more battery case; and one or more fluid circulation device configured to circulate the heat transfer fluid through the one or more battery case containing one or more batteries that are at least partially submerged within the heat transfer fluid contained inside the one or more battery case, wherein the one or more battery case is configured to transfer the heat from the heat transfer fluid contained inside the one or more battery case into the atmosphere.
  • the one or more fluid circulation device is selected from the group comprising at least one of a pump, blower, fan, compressor or their combinations.
  • the one or more fluid circulation device is configured to generate a flow in the heat transfer fluid to transfer the heat from the one or more batteries to the heat transfer fluid, and further transfer the heat from the heat transfer fluid to the one or more battery case.
  • the one or more battery case acts as a heat exchanger that transfers the heat from the heat transfer fluid contained inside the one or more battery case into the atmosphere.
  • the one or more battery case comprises a plurality of heat transfer mediums on its surface to facilitate the transferring of heat into the atmosphere.
  • the heat transfer fluid is selected from a dielectric cooling heat transfer fluid to cut off air supply to the one or more batteries in an event of fire hazard.
  • the system comprises one or more temperature sensors to determine the temperature of the one or more batteries at least partially submerged within the heat transfer fluid.
  • the system comprises a processor configured to turn on the one or more fluid circulation device when the temperature determined by the one or more temperature sensors of at least a battery from the one or more batteries exceeds a predetermined value.
  • the processor is configured to turn off the one or more fluid circulation device when the temperature of all the batteries from the one or more batteries are below the predetermined value.
  • the one or more heating elements at least partially submerged within the heat transfer fluid are contained in one or more battery case, wherein the heat generated by the one or more heating elements is first transferred from the heating element to the heat transfer fluid and thereafter from the fluid to the one or more batteries inside the one or more battery casings.
  • embodiments of the present disclosure provide an apparatus for battery thermal management, wherein the apparatus comprises: one or more battery case; one or more batteries configured to be at least partially submerged within a heat transfer fluid contained in the one or more battery case; one or more fluid circulation device configured to circulate the heat transfer fluid through the one or more batteries that is at least partially submerged within the heat transfer fluid contained inside the one or more battery case, wherein the one or more battery case is configured to transfer the heat from the heat transfer fluid contained inside the one or more battery case into the atmosphere; one or more temperature sensors for determining the temperature of the one or more batteries at least partially submerged within the heat transfer fluid; and a processor that is configured to: turn on the one or more fluid circulation device when the temperature of at least a battery from the one or more batteries exceeds a predetermined value.
  • the processor is configured to turn off the one or more fluid circulation device when the temperature of all the batteries from the one or more batteries are below the predetermined value.
  • the one or more fluid circulation device is selected from the group comprising at least one of a pump, blower, fan, compressor or their combinations.
  • the one or more fluid circulation device is configured to generate a flow in the heat transfer fluid to transfer the heat from the one or more batteries to the heat transfer fluid, and further transfer the heat from the heat transfer fluid to the one or more battery case.
  • the one or more battery case acts as a heat exchanger that transfers the heat from the heat transfer fluid contained inside the one or more battery case into the atmosphere.
  • the one or more battery case comprises a plurality of heat transfer mediums on its surface to facilitate the transferring of heat into the atmosphere.
  • the heat transfer fluid is selected from a dielectric cooling heat transfer fluid to cut off air supply to the one or more batteries in an event of fire hazard.
  • the one or more heating elements at least partially submerged within the heat transfer fluid are contained in one or more battery case, wherein the heat generated by the one or more heating elements is first transferred from the heating element to the heat transfer fluid and thereafter from the fluid to the one or more batteries inside the one or more battery casings.
  • embodiments of the present disclosure provide a method for battery thermal management, wherein the method comprises: determining via one or more sensors, temperature of one or more batteries, wherein the one or more batteries are at least partially submerged within a heat transfer fluid contained in one or more battery case; determining via a processor, if the temperature of at least one of a battery from the one or more batteries exceeds a predetermined value; and commanding via the processor, to turn on one or more fluid circulation device.
  • the method comprises determining via a processor if the temperature of at least one of a battery from the one or more batteries is below a predetermined value.
  • the method comprises commanding via the processor to turn off the one or more fluid circulation device.
  • FIG. 1 is a schematic illustration of a battery thermal management system, in accordance with an embodiment of the present disclosure.
  • FIG. 2a is a schematic illustration of a battery thermal management system, in accordance with another embodiment of the present disclosure.
  • FIG. 2b is a schematic illustration of a pump and channel assembly, in accordance with an embodiment of the present disclosure.
  • FIG. 3 is a schematic illustration of a heat transfer surface of one or more battery casing, in accordance with an embodiment of the present disclosure.
  • FIG. 4 is a schematic illustration of a flow diagram of a method of battery thermal management, in accordance with an embodiment of the present disclosure.
  • an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent.
  • a non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item to which the arrow is pointing.
  • embodiments of the present disclosure provide a system for battery thermal management, wherein the system comprises: one or more battery case; one or more batteries configured to be at least partially submerged within a heat transfer fluid contained in the one or more battery case; and one or more fluid circulation device configured to circulate the heat transfer fluid through the one or more battery case containing one or more batteries that are at least partially submerged within the heat transfer fluid contained inside the one or more battery case, wherein the one or more battery case is configured to transfer the heat from the heat transfer fluid contained inside the one or more battery case into the atmosphere.
  • embodiments of the present disclosure provide an apparatus for battery thermal management, wherein the apparatus comprises: one or more battery case; one or more batteries configured to be at least partially submerged within a heat transfer fluid contained in the one or more battery case; one or more fluid circulation device configured to circulate the heat transfer fluid through the one or more batteries that is at least partially submerged within the heat transfer fluid contained inside the one or more battery case, wherein the one or more battery case is configured to transfer the heat from the heat transfer fluid contained inside the one or more battery case into the atmosphere; one or more temperature sensors for determining the temperature of the one or more batteries at least partially submerged within the heat transfer fluid; and a processor that is configured to: turn on the one or more fluid circulation device when the temperature of at least a battery from the one or more batteries exceeds a predetermined value.
  • embodiments of the present disclosure provide a method for battery thermal management, wherein the method comprises: determining via one or more sensors, temperature of one or more batteries, wherein the one or more batteries are at least partially submerged within a heat transfer fluid contained in one or more battery case; determining via a processor, if the temperature of at least one of a battery from the one or more batteries exceeds a predetermined value; and commanding via the processor, to turn on one or more fluid circulation device.
  • the present disclosure relates to a method, system, and apparatus for active (or passive) thermal management and thermal runaway prevention for high energy density battery packs.
  • the present disclosure provides the battery thermal management for battery packs of any chemistry that require cooling and thermal runaway protection.
  • the disclosed system for battery thermal management comprises a battery case, one or more batteries, heat transfer fluid and so forth.
  • one or more batteries are at least partially submerged within a liquid contained within the battery case.
  • the system further comprises at least one fluid circulation device to circulate the heat transfer fluid via one or more channels from the battery case to a cooling unit back to the battery case.
  • the method and system disclosed herein provide a system for active thermal management of one or more batteries using Immersion Cooling.
  • the one or more batteries are combined together to form one or more battery modules.
  • the assembly for battery thermal management employed herein is compact and lightweight wherein the battery casing is being used as a heat exchanger.
  • the disclosed system provides a battery thermal runaway prevention.
  • the active fluid immersion cooling for battery cells facilitates in improving thermal performance of one or more batteries.
  • the ability to prevent or contain thermal runaway in one or more batteries provides safety enhancement and battery life longevity to a great extent.
  • the system described herein solves two primary concerns with respect to battery thermal management to ensure safety and long life of a battery. These two primary concerns are: (1) to maintain a uniform temperature range between the one or more batteries and (2) protecting the one or more batteries against thermal runaway situations. In an example, the one or more batteries must be maintained at a uniform temperature in the range of 25-35 degree Celsius. Furthermore, in another embodiment, the system discloses a unique mechanism that provides protection of one or more batteries against thermal runaway conditions by controlling and isolating damaged or abused batteries and mitigating the spread of a thermal runaway condition.
  • the system for battery thermal management comprises one or more battery case, one or more batteries configured to be at least partially submerged within a heat transfer fluid contained in the one or more battery case and one or more fluid circulation device configured to circulate the heat transfer fluid through the one or more batteries that are at least partially submerged within the heat transfer fluid contained inside the one or more battery case, wherein the one or more battery case is configured to transfer the heat from the heat transfer fluid contained inside the one or more battery case into the atmosphere.
  • the one or more battery case acts as a heat exchanger that transfers the heat from the heat transfer fluid contained inside the one or more battery case into the atmosphere.
  • the one or more battery casing acts as an interface for transferring heat from the one or more batteries to the atmosphere. The heat generated from the one or more batteries is transferred to the heat transfer fluid and thereby transferred to the battery casing from the heat transfer fluid and then to the atmosphere.
  • employing the one or more battery casing as a heat exchanger provides several advances namely elimination of parts (radiator, pump, coolant hoses, connectors), reduction of overall length of fluid flow path, Cost reduction, weight reduction, simplicity of manufacturing , better serviceability, ease of modularity, thermal faults localized to individual battery packs i.e., no heat transfer between consecutive battery packs, possibility of splitting individual battery modules based on space availability inside vehicle (electrically connected modules in such cases), no need for thermal coupling since thermal management is independent for each battery module; possibility of easy battery swapping function (no need for thermal and fluid decoupling, only electrical and mechanical decoupling required for battery swap, thereby reducing time and effort and further reducing the down time).
  • the one or more battery case comprises a heat transfer surfaces on its surface to facilitate the transferring of heat into the atmosphere.
  • the heat transfer surfaces over the one or more battery casing comprises a plurality of fins and/or any other geometric surfaces for facilitating transfer of heat from the heat transfer fluid to the casing and then to the atmosphere.
  • the plurality of fins comprises at least one of Straight fins, Radial fins, Annular fins, Pin fins, and dimples.
  • the disclosed system employs direct fluid immersion that puts substantially the entire surface area of the battery cell in direct thermal contact with the heat transfer fluid.
  • the direct thermal contact of the one or more batteries with the heat transfer fluid when immersed in the heat transfer fluid eliminates the mass, weight, volume, and cost associated with adding tubes and cooling plates to the system. Furthermore, mass, weight, volume and cost associated with heat sinks, cooling plates, support structures and/or phase change materials are also eliminated.
  • heat transfer fluids with boiling points chosen appropriately performs the function of the phase change materials without incurring any additional mass, volume, or cost and can safely and completely remove all the energy associated with a one or more batteries. Failing to do so may catastrophically affect the one or more batteries.
  • the one or more batteries are packed tightly together that reduces the overall volume of the batteries or battery modules without compromising on the heat transfer from the batteries to the fluid or risking a thermal runaway event spreading from one battery to another consecutive battery.
  • the disclosed system for battery thermal management comprising one or more battery case, one or more batteries, heat transfer fluid, fluid circulation device and so forth.
  • one or more batteries are at least partially submerged within a liquid contained within the one or more battery case.
  • the system comprises one or more fluid circulation device configured to circulate the heat transfer fluid through the one or more battery case containing one or more batteries that are at least partially submerged within the heat transfer fluid contained inside the one or more battery case.
  • the one or more fluid circulation device is selected from the group comprising at least one of a pump, blower, fan, compressor, internal ducts with orifices or their combinations.
  • the one or more fluid circulation device is configured to generate a swirl motion in the heat transfer fluid to transfer the heat from the one or more batteries to the heat transfer fluid, and thereby transfer the heat from the heat transfer fluid to the one or more battery case.
  • heat transfer fluids are commercially available that are designed for heat transfer applications which have boiling points appropriate to heat absorbing and further heat transferring applications.
  • the heat transfer fluids employed herein have negligible toxicity (biologically inert), have no ozone depletion potential, have low greenhouse gas potential, are non-flammable, and have other mechanical properties favourable for said battery thermal management system.
  • the system operates at atmospheric pressure and, thus, puts no additional mechanical stress on individual one or more batteries, and requires no additional mass or reinforcement of the one or more battery container that would be required as a pressure vessel.
  • the heat transfer fluid is circulated through the one or more batteries with minimal effort in order to ensure uniform temperature distribution and cooled with the one or more battery casing as a standard heat exchanger in order to keep the battery well within the desirable temperature range, thus extending the usable life of the battery.
  • the present disclosure employs a dielectric heat transfer fluid for transferring the heat from the one or more batteries to the atmosphere.
  • the heat transfer fluids are used in processes where cooling or heating is required to obtain and maintain a particular temperature.
  • employing the dielectric heat transfer fluid cuts out oxygen supply to the one or more batteries, thereby providing protection against fires caused in case of short-circuits overcurrent, overvoltage, cell rupture and thermal runaway. Consequently, the one or more batteries are safely discharged to zero voltage during such events without occurrence of fire.
  • the chemistries that are used as heat transfer fluids are fully synthetic dielectric ester, Naphthenic based and Paraffinic based oils are used and can also be used up with a proper additive package.
  • the system comprises one or more temperature sensors to determine the temperature of the one or more batteries at least partially submerged within the heat transfer fluid.
  • the one or more temperature sensor involves sensing a temperature of one or more batteries.
  • one or more batteries are at least partially submerged within a heat transfer fluid contained within the one or more battery case.
  • the system comprises a processor configured to turn on the one or more fluid circulation devices when the temperature determined by the one or more temperature sensors of at least a battery from the one or more batteries exceeds a predetermined value.
  • the processor is configured to turn off the one or more fluid circulation devices when the temperature of all the batteries from the one or more batteries are below the predetermined value.
  • the processor comprises at least one microcontroller that sense the temperature of one or more batteries with the calibrated predetermined value.
  • the system comprises a processor that controls the stage- wise switching on/off the fluid circulation device.
  • the processor comprises a microcontroller that control the stage wise turning on/off the fluid circulation device fans based on temperature comparison of the one or more batteries with the predetermined threshold value of the one or more batteries.
  • the one or more fluid circulation device is switched on by the processor when at least one temperature sensor detects value above the predetermined threshold value.
  • the one or more fluid circulation device is configured to generate a flow in the heat transfer fluid to accelerate the transfer the heat from the one or more batteries to the heat transfer fluid, and further to accelerate the transfer of heat from the heat transfer fluid to the one or more battery case.
  • the one or more fluid circulation device comprises one or more fans internally attached to the one or more battery casing.
  • the one or more fluid circulation device comprises one or more (submerged) pumps internally fitted inside the one or more battery casing.
  • the one or more fans and/or one or more pumps are internally connected to the one or more battery casing.
  • the system herein generates a swirl motion via one or more fluid circulation device to carry heat from one or more batteries to heat transfer fluid to casing and then to atmosphere via battery casing.
  • the fluid circulation devices such as pumps, blowers, compressors and so forth are configured to provide internal circulation of heat transfer fluid through the one or more batteries so as transferring the heat from one or more batteries to the heat transfer fluids.
  • the one or more fluid circulation device is further configured to make the heat transfer fluids to flow across the higher temperature zones associated with the one or more batteries.
  • the processor analyses the temperature sensor data and identifies the one or more higher temperature zonesassociated with the one or more batteries and arranges the flow of heat transfer fluid in such a way that flow will occur majorly across the higher temperature zones associated with the one or more batteries.
  • the processor works in conjunction with the one or more temperature sensors to identify the higher temperature zones associated with the one or more batteries.
  • identifying the higher temperature zones associated with the one or more batteries and thereafter configuring the flow of heat transfer fluid majorly through those higher temperature zones results in increasing the efficiency of battery thermal management system.
  • the power input required to operate the fluid circulation devices may also be reduced to great extent by employing the above-mentioned configuration.
  • the system comprises one or more temperature sensors that determines the temperature of one or more batteries.
  • a processor is also described herein that analyses and compares the temperatures of one or more batteries with the calibrated temperature predetermined threshold value.
  • the processor further controls the stage-wise switching off of fluid circulation device, based on temperature comparison.
  • the processor switches off the one or more fluid circulation device when all the temperature sensors detect temperature below the predetermined threshold value.
  • the one or more fluid circulation device configures the flow of heat transfer fluids through the one or more batteries.
  • the processor herein controls the one or more fluid circulation device to make the flow of the heat transfer fluid in a packetized form.
  • flowing of the heat transfer fluids in a packetized form makes the system more efficient.
  • the packetized form refers to providing only a certain amount of fluid across the one or more batteries in a certain interval of time. The fluids recurrently flow in packets in a predefined interval of time.
  • the one or more heating elements are also disclosed that are at least partially submerged within the heat transfer fluid and are contained in one or more battery case, wherein the heat generated by the one or more heating elements are first transferred from the heating element to the heat transfer fluid and thereafter from the fluid to the one or more batteries inside the one or more battery casings.
  • the present disclosure also relates to an apparatus for battery thermal management system, wherein the apparatus comprises one or more battery case, one or more batteries configured to be at least partially submerged within a heat transfer fluid contained in the one or more battery case, one or more fluid circulation device configured to circulate the heat transfer fluid through the one or more batteries that is at least partially submerged within the heat transfer fluid contained inside the one or more battery case, wherein the one or more battery case is configured to transfer the heat from the heat transfer fluid contained inside the one or more battery case into the atmosphere. Furthermore, one or more temperature sensors are also provided, for determining the temperature of the one or more batteries at least partially submerged within the heat transfer fluid.
  • the system comprises a processor that is configured to turn on the one or more fluid circulation device when the temperature of at least a battery from the one or more batteries exceeds a predetermined value.
  • the one or more temperature sensor determines the temperature of the one or more batteries.
  • the processor(s) compares the temperature of the one or more batteries with a predetermined maximum threshold value (e.g., this temperature may be a predefined maximum temperature specified by the manufacturer of the one or more batteries). If the processor(s) determines that the temperature of the one or more batteries is above the predetermined threshold temperature value, the processor(s) will command (e.g., by sending a command signal to) a cooling unit to be activated (e.g., turned on).
  • the cooling unit comprises one or more fluid circulating device.
  • the cooling unit employs a radiator-type structure. In some embodiments, the cooling unit also employs a fan to aid in the cooling process.
  • the system comprises a fan type circulation of the battery thermal management system.
  • the one or more fluid circulation device comprises of one or more fans or blowers.
  • the cooling unit comprises a fan internally mounted in the one or more battery casing. Employing one or more fans internally connected to the one or more battery casing leads to providing a compact structure.
  • the one or more fans are structured in such a way that a flow (for example in the form of swirl motion) in the heat transfer fluid is generated to transfer the heat from the one or more batteries to the heat transfer fluid, and further transfer the heat from the heat transfer fluid to the one or more battery case.
  • the cooling unit comprises one or more fans externally mounted on the one or more battery casing. In accordance with the above embodiments described above, the number of fans depend on the battery size. Larger the battery size, more will be the number of fans.
  • the system comprises a channel type circulation system that further comprises one or more duct type fluid circulation device.
  • the system comprises one or more pumps that facilitates in transferring the heat transfer fluid to the higher temperature zones of one or more batteries.
  • the fluid circulation device according to this embodiment (in an example, the pump) takes in the heat transfer fluid via the fluid inlet and make the heat transfer fluid flow through the at least one duct.
  • the one or more hotspots are determined by the processor by analysing the temperature readings of one or more temperature sensors.
  • the duct type circulation system comprises at least one duct that defines the path of circulation of the heat transfer fluids. Said at least one duct comprises at least one duct outlet that spray or transfer the heat transfer fluid to the determined higher temperature zones of the one or more batteries.
  • the number of pumps depend on the battery size. Larger the battery size, more will be the number of pumps.
  • the one or more battery case comprises a plurality of fins or any other geometric structure on its surface for facilitating the heat transfer from one or more batteries to the atmosphere.
  • the heat generated from the one or more batteries is transferred from the one or more batteries to the heat transfer fluid.
  • the heat transfer fluid absorbs the heat from the one or more batteries. The heat further transfers from the heat transfer fluid to the atmosphere via the battery casing.
  • the processor is configured to turn off the one or more fluid circulation device when the temperature of all the batteries from the one or more batteries are below the predetermined value.
  • the one or more battery case comprises a plurality of fins or other geometric heat transfer mediums on its surface to facilitate the transferring of heat into the atmosphere.
  • the present disclosure also relates to the method for battery thermal management system, wherein the method comprises determining via one or more sensors, temperature of one or more batteries, wherein the one or more batteries are at least partially submerged within a heat transfer fluid contained in one or more battery case.
  • the method further comprises determining via a processor, if the temperature of at least one of a battery from the one or more batteries exceeds a predetermined value and further commanding via the processor, to turn on one or more fluid circulation device.
  • the system comprises one or more temperature sensors, one or more fluid circulation device, a processor, dielectric fluid, one or more battery pack including cells, bus-bars and connectors, couplers and wires.
  • the processor includes a microcontroller that determines the temperature of one or more submerged one or more batteries within the one or more battery casing.
  • the processor is configured to analyse and compare the sensed temperature with the calibrated predetermined temperature threshold value.
  • the processor or microcontroller controls the stage wise turning on of the one or more fluid circulation device based on temperature comparison. In an example, the processor turns on the one or more fluid circulation device when one or more temperature sensor detects value above a certain predetermined threshold value.
  • the heat transfer fluid inside the battery casing carry heat from one or more batteries to heat transfer fluid and further to casing and thereafter to the atmosphere via battery casing as the one or more battery casing acts as a heat exchanger or a heat transfer interface.
  • the processor or microcontroller analyses and compares the sensed temperature of one or more batteries with the calibrated predetermined temperature threshold values. Based on the comparison of the sensed temperature with the predetermined temperature threshold value, the processor or microcontroller controls the stage wise turning off of the one or more fluid circulation device. In an example, the one or more fluid circulation device is turned off when the temperature of all the temperature sensors in the system are below a certain predetermined temperature threshold value.
  • the system 100 comprises one or more batteries 102, one or more battery casing 104, a battery management system 106, fluid circulation device 108, and a heat transfer fluid 110.
  • the system further comprises a bottom mounting plate 112 configured to support the one or more battery casing.
  • the one or more fluid circulation device is selected from at least one of fan and/or blower that are arranged either internally and/or externally to the one or more battery casing 104.
  • the battery management system 106 comprises a processor that is configured to monitor and/or control the overall operations of battery management system.
  • the processor configured to turn on the one or more fluid circulation device when the temperature determined by the one or more temperature sensors of at least a battery from the one or more batteries exceeds a predetermined value.
  • the heat transfer fluid flows across the one or more batteries 102 in the battery casing 104 to absorb heat from the one or more batteries 102.
  • the heat is being transferred from the one or more batteries to the heat transfer fluid and thereafter from the heat transfer fluid to the atmosphere via the battery casing 104.
  • the processor is configured to turn off the one or more fluid circulation device when the temperature of all the batteries from the one or more batteries are below the predetermined value.
  • the processor comprises at least one microcontroller that sense the temperature of one or more batteries with the calibrated predetermined value.
  • FIG. 2a there is shown a schematic illustration of a battery thermal management system 200, in accordance with another embodiment of the present disclosure.
  • FIG. 2b shows the schematic illustration of a pump and channel assembly 250 in accordance with an embodiment of the present disclosure.
  • the system 200 comprises one or more batteries 202, one or more battery casing 204, a battery management system 206, fluid circulation device 208, and heat transfer fluid 210.
  • the system further comprises a bottom mounting plate 212 configured to support the one or more battery casing.
  • the one or more fluid circulation device is selected from the at least one pump, wherein the heat transfer fluid 210 is being pumped by the one or more pumps in the one or more channels or ducts or tubes 216.
  • the one or more ducts 216 comprises one or more duct outlet 218 that spray or outlet the heat transfer fluid to the one or more hotspot associated with the one or more batteries.
  • the one or more duct outlet 218 sprays or outlets the heat transfer fluid to the over the one or more batteries and/or across the one or more batteries.
  • the battery management system 206 further comprises a processor that is configured to monitor the operations of whole battery management system.
  • the processor configured to turn on the one or more fluid circulation device when the temperature determined by the one or more temperature sensors of at least a battery from the one or more batteries exceeds a predetermined value.
  • the processor is configured to turn off the one or more fluid circulation device when the temperature of all the batteries from the one or more batteries are below the predetermined value.
  • the processor comprises at least one microcontroller that sense the temperature of one or more batteries with the calibrated predetermined value.
  • the surface 302 comprises one or more heat transferrable mediums 304 for facilitating heat transfer from the heat transfer fluid to the atmosphere.
  • the heat transfer medium comprises a plurality of fins or other heat transfer surfaces for providing heat transfer surface from the heat transfer fluid to the atmosphere via one or more battery casing.
  • the plurality of fins comprising at least one of Straight fins, Radial fins, Annular fins, and Pin fins.
  • the method comprises determining via one or more sensors, temperature of one or more batteries, wherein the one or more batteries are at least partially submerged within a heat transfer fluid contained in one or more battery case.
  • the method comprises determining via a processor, if the temperature of at least one of a battery from the one or more batteries exceeds a predetermined value.
  • the method comprising commanding via the processor, to turn on one or more fluid circulation device.

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Abstract

A system for battery thermal management, wherein the system comprises one or more battery case, one or more batteries and one or more fluid circulation device. The one or more batteries are configured to be at least partially submerged within a heat transfer fluid contained in the one or more battery case and one or more fluid circulation devices are configured to circulate the heat transfer fluid through the one or more battery case containing one or more batteries that are at least partially submerged within the heat transfer fluid contained inside the one or more battery case, wherein the one or more battery case is configured to transfer the heat from the heat transfer fluid contained inside the one or more battery case into the atmosphere.

Description

SYSTEM AND METHOD FOR BATTERY THERMAL MANAGEMENT
FIELD OF INVENTION
In general, the present disclosure is related to a system and method for thermal management of batteries. In particular, the present disclosure relates to a system and method for active (or passive) thermal management of batteries wherein the thermal management includes submerging one or more cells or batteries inside the heat transfer fluid.
BACKGROUND
Batteries such as lithium-ion or sodium- ion batteries (or any other class of batteries) generate heat during operation and recharging. When the batteries are subjected to overheating or being exposed to high-temperature environments, undesirable effects occur in battery systems and that can impact the overall operations of batteries. In extreme cases, overheated batteries are known to suffer catastrophic failure such as Thermal Runaway, explosions and fires. Cooling systems are typically employed known as battery thermal management system that mitigate undesirable overheating conditions.
Conventional cooling systems for cooling batteries employ coolant fluids passing through pipes, tubes, or other channels where some portions of the individual battery cells are in contact with the fluid channel or have a path to reject heat to the channel, either through contact with a thermally conductive component (e.g., a heat sink) or through direct contact with other battery cells. Conventional methods typically suffer from the limitations of limited contact area with individual battery cells and poor thermal conduction across the contact area. Furthermore, these methods have several components through which heat from the batteries must travel to reach the ultimate cooling fluid, thereby resulting in the limited ability to effectively remove heat. In addition, these measures introduce significant additional mass and volume to the battery pack that reduce the volume, weight, and effectiveness of the battery pack while increasing cost. Moreover, conventional battery thermal management systems provide limited or no significant protection from thermal runaway events. There exists another system for thermal management of battery packs that involve immersing the cells in a cooling fluid along with a Single Heat Exchanger for all battery modules. Hot cooling fluid is pumped to said heat exchanger and cold fluid is sent back to battery module. Longer lengths of fluid flow paths reduce system efficiency (through frictional losses during fluid flow), leads to large component count that give rise to higher costs and weight, complicated cooling system design, and inferior serviceability. Due to thermal coupling of battery modules or one or more batteries, if one battery or a single battery module overheats, then the cooling fluid will carry heat from that pack to consecutive packs, thereby increasing the consecutive battery’s temperatures as well. Such systems also suffer from the difficulties such as battery module removal, maintenance and having difficulties in battery swapping function. In such scenarios where battery swapping is required, it becomes absolute necessary to drain the cooling fluid completely, whenever an individual battery-module pack is to be swapped / removed.
Therefore, in light of the foregoing discussion, there exists a need to overcome the aforementioned drawbacks in the battery thermal management system.
SUMMARY
An object of the present disclosure is to provide a system and method for thermal management of batteries.
Another object of the present disclosure is to provide an apparatus for thermal management of batteries.
Another object of the present disclosure is to provide a method for thermal management of batteries.
Yet another object of the present disclosure is to provide a system for providing protection to battery-cells from thermal runaway.
In a first aspect, embodiments of the present disclosure provide a system for battery thermal management, wherein the system comprises: one or more battery case; one or more batteries configured to be at least partially submerged within a heat transfer fluid contained in the one or more battery case; and one or more fluid circulation device configured to circulate the heat transfer fluid through the one or more battery case containing one or more batteries that are at least partially submerged within the heat transfer fluid contained inside the one or more battery case, wherein the one or more battery case is configured to transfer the heat from the heat transfer fluid contained inside the one or more battery case into the atmosphere.
Optionally, the one or more fluid circulation device is selected from the group comprising at least one of a pump, blower, fan, compressor or their combinations.
Optionally, the one or more fluid circulation device is configured to generate a flow in the heat transfer fluid to transfer the heat from the one or more batteries to the heat transfer fluid, and further transfer the heat from the heat transfer fluid to the one or more battery case.
Optionally, the one or more battery case acts as a heat exchanger that transfers the heat from the heat transfer fluid contained inside the one or more battery case into the atmosphere.
Optionally, the one or more battery case comprises a plurality of heat transfer mediums on its surface to facilitate the transferring of heat into the atmosphere.
Optionally, the heat transfer fluid is selected from a dielectric cooling heat transfer fluid to cut off air supply to the one or more batteries in an event of fire hazard.
Optionally, the system comprises one or more temperature sensors to determine the temperature of the one or more batteries at least partially submerged within the heat transfer fluid. Optionally, the system comprises a processor configured to turn on the one or more fluid circulation device when the temperature determined by the one or more temperature sensors of at least a battery from the one or more batteries exceeds a predetermined value.
Optionally, the processor is configured to turn off the one or more fluid circulation device when the temperature of all the batteries from the one or more batteries are below the predetermined value.
Optionally, the one or more heating elements at least partially submerged within the heat transfer fluid are contained in one or more battery case, wherein the heat generated by the one or more heating elements is first transferred from the heating element to the heat transfer fluid and thereafter from the fluid to the one or more batteries inside the one or more battery casings.
In a second aspect, embodiments of the present disclosure provide an apparatus for battery thermal management, wherein the apparatus comprises: one or more battery case; one or more batteries configured to be at least partially submerged within a heat transfer fluid contained in the one or more battery case; one or more fluid circulation device configured to circulate the heat transfer fluid through the one or more batteries that is at least partially submerged within the heat transfer fluid contained inside the one or more battery case, wherein the one or more battery case is configured to transfer the heat from the heat transfer fluid contained inside the one or more battery case into the atmosphere; one or more temperature sensors for determining the temperature of the one or more batteries at least partially submerged within the heat transfer fluid; and a processor that is configured to: turn on the one or more fluid circulation device when the temperature of at least a battery from the one or more batteries exceeds a predetermined value.
Optionally, the processor is configured to turn off the one or more fluid circulation device when the temperature of all the batteries from the one or more batteries are below the predetermined value.
Optionally, the one or more fluid circulation device is selected from the group comprising at least one of a pump, blower, fan, compressor or their combinations.
Optionally, the one or more fluid circulation device is configured to generate a flow in the heat transfer fluid to transfer the heat from the one or more batteries to the heat transfer fluid, and further transfer the heat from the heat transfer fluid to the one or more battery case.
Optionally, the one or more battery case acts as a heat exchanger that transfers the heat from the heat transfer fluid contained inside the one or more battery case into the atmosphere.
Optionally, the one or more battery case comprises a plurality of heat transfer mediums on its surface to facilitate the transferring of heat into the atmosphere.
Optionally, the heat transfer fluid is selected from a dielectric cooling heat transfer fluid to cut off air supply to the one or more batteries in an event of fire hazard.
Optionally, the one or more heating elements at least partially submerged within the heat transfer fluid are contained in one or more battery case, wherein the heat generated by the one or more heating elements is first transferred from the heating element to the heat transfer fluid and thereafter from the fluid to the one or more batteries inside the one or more battery casings. In a third aspect, embodiments of the present disclosure provide a method for battery thermal management, wherein the method comprises: determining via one or more sensors, temperature of one or more batteries, wherein the one or more batteries are at least partially submerged within a heat transfer fluid contained in one or more battery case; determining via a processor, if the temperature of at least one of a battery from the one or more batteries exceeds a predetermined value; and commanding via the processor, to turn on one or more fluid circulation device.
Optionally, the method comprises determining via a processor if the temperature of at least one of a battery from the one or more batteries is below a predetermined value.
Optionally, the method comprises commanding via the processor to turn off the one or more fluid circulation device.
Additional aspects, advantages, features and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative embodiments construed in conjunction with the appended claims that follow.
It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.
A better understanding of the present invention may be obtained through the following examples which are set forth to illustrate but are not to be construed as limiting the present invention.
BRIEF DESCRIPTION OF DRAWINGS The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.
Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:
FIG. 1 is a schematic illustration of a battery thermal management system, in accordance with an embodiment of the present disclosure.
FIG. 2a is a schematic illustration of a battery thermal management system, in accordance with another embodiment of the present disclosure.
FIG. 2b is a schematic illustration of a pump and channel assembly, in accordance with an embodiment of the present disclosure.
FIG. 3 is a schematic illustration of a heat transfer surface of one or more battery casing, in accordance with an embodiment of the present disclosure.
FIG. 4 is a schematic illustration of a flow diagram of a method of battery thermal management, in accordance with an embodiment of the present disclosure.
In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item to which the arrow is pointing.
DETAILED DESCRIPTION The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognise that other embodiments for carrying out or practising the present disclosure are also possible.
In a first aspect, embodiments of the present disclosure provide a system for battery thermal management, wherein the system comprises: one or more battery case; one or more batteries configured to be at least partially submerged within a heat transfer fluid contained in the one or more battery case; and one or more fluid circulation device configured to circulate the heat transfer fluid through the one or more battery case containing one or more batteries that are at least partially submerged within the heat transfer fluid contained inside the one or more battery case, wherein the one or more battery case is configured to transfer the heat from the heat transfer fluid contained inside the one or more battery case into the atmosphere.
In a second aspect, embodiments of the present disclosure provide an apparatus for battery thermal management, wherein the apparatus comprises: one or more battery case; one or more batteries configured to be at least partially submerged within a heat transfer fluid contained in the one or more battery case; one or more fluid circulation device configured to circulate the heat transfer fluid through the one or more batteries that is at least partially submerged within the heat transfer fluid contained inside the one or more battery case, wherein the one or more battery case is configured to transfer the heat from the heat transfer fluid contained inside the one or more battery case into the atmosphere; one or more temperature sensors for determining the temperature of the one or more batteries at least partially submerged within the heat transfer fluid; and a processor that is configured to: turn on the one or more fluid circulation device when the temperature of at least a battery from the one or more batteries exceeds a predetermined value.
In a third aspect, embodiments of the present disclosure provide a method for battery thermal management, wherein the method comprises: determining via one or more sensors, temperature of one or more batteries, wherein the one or more batteries are at least partially submerged within a heat transfer fluid contained in one or more battery case; determining via a processor, if the temperature of at least one of a battery from the one or more batteries exceeds a predetermined value; and commanding via the processor, to turn on one or more fluid circulation device.
The present disclosure relates to a method, system, and apparatus for active (or passive) thermal management and thermal runaway prevention for high energy density battery packs. In an embodiment, the present disclosure provides the battery thermal management for battery packs of any chemistry that require cooling and thermal runaway protection. The disclosed system for battery thermal management comprises a battery case, one or more batteries, heat transfer fluid and so forth. In another embodiment, one or more batteries are at least partially submerged within a liquid contained within the battery case. In yet another embodiment, the system further comprises at least one fluid circulation device to circulate the heat transfer fluid via one or more channels from the battery case to a cooling unit back to the battery case.
The method and system disclosed herein provide a system for active thermal management of one or more batteries using Immersion Cooling. In an embodiment, the one or more batteries are combined together to form one or more battery modules. The assembly for battery thermal management employed herein is compact and lightweight wherein the battery casing is being used as a heat exchanger. Advantageously, the disclosed system provides a battery thermal runaway prevention. Furthermore, the active fluid immersion cooling for battery cells facilitates in improving thermal performance of one or more batteries. The ability to prevent or contain thermal runaway in one or more batteries provides safety enhancement and battery life longevity to a great extent.
In accordance with an embodiment of the present disclosure, the system described herein solves two primary concerns with respect to battery thermal management to ensure safety and long life of a battery. These two primary concerns are: (1) to maintain a uniform temperature range between the one or more batteries and (2) protecting the one or more batteries against thermal runaway situations. In an example, the one or more batteries must be maintained at a uniform temperature in the range of 25-35 degree Celsius. Furthermore, in another embodiment, the system discloses a unique mechanism that provides protection of one or more batteries against thermal runaway conditions by controlling and isolating damaged or abused batteries and mitigating the spread of a thermal runaway condition.
The system for battery thermal management is described herein. The system comprises one or more battery case, one or more batteries configured to be at least partially submerged within a heat transfer fluid contained in the one or more battery case and one or more fluid circulation device configured to circulate the heat transfer fluid through the one or more batteries that are at least partially submerged within the heat transfer fluid contained inside the one or more battery case, wherein the one or more battery case is configured to transfer the heat from the heat transfer fluid contained inside the one or more battery case into the atmosphere.
In an embodiment, the one or more battery case acts as a heat exchanger that transfers the heat from the heat transfer fluid contained inside the one or more battery case into the atmosphere. Herein, the one or more battery casing acts as an interface for transferring heat from the one or more batteries to the atmosphere. The heat generated from the one or more batteries is transferred to the heat transfer fluid and thereby transferred to the battery casing from the heat transfer fluid and then to the atmosphere. Beneficially, employing the one or more battery casing as a heat exchanger provides several advances namely elimination of parts (radiator, pump, coolant hoses, connectors), reduction of overall length of fluid flow path, Cost reduction, weight reduction, simplicity of manufacturing , better serviceability, ease of modularity, thermal faults localized to individual battery packs i.e., no heat transfer between consecutive battery packs, possibility of splitting individual battery modules based on space availability inside vehicle (electrically connected modules in such cases), no need for thermal coupling since thermal management is independent for each battery module; possibility of easy battery swapping function (no need for thermal and fluid decoupling, only electrical and mechanical decoupling required for battery swap, thereby reducing time and effort and further reducing the down time).
According to an embodiment, the one or more battery case comprises a heat transfer surfaces on its surface to facilitate the transferring of heat into the atmosphere. The heat transfer surfaces over the one or more battery casing comprises a plurality of fins and/or any other geometric surfaces for facilitating transfer of heat from the heat transfer fluid to the casing and then to the atmosphere. In another embodiment, the plurality of fins comprises at least one of Straight fins, Radial fins, Annular fins, Pin fins, and dimples. In an embodiment, the disclosed system employs direct fluid immersion that puts substantially the entire surface area of the battery cell in direct thermal contact with the heat transfer fluid. Employing the direct thermal contact of the one or more batteries with the heat transfer fluid, when immersed in the heat transfer fluid eliminates the mass, weight, volume, and cost associated with adding tubes and cooling plates to the system. Furthermore, mass, weight, volume and cost associated with heat sinks, cooling plates, support structures and/or phase change materials are also eliminated. In an embodiment, heat transfer fluids with boiling points chosen appropriately performs the function of the phase change materials without incurring any additional mass, volume, or cost and can safely and completely remove all the energy associated with a one or more batteries. Failing to do so may catastrophically affect the one or more batteries. In another embodiment, the one or more batteries are packed tightly together that reduces the overall volume of the batteries or battery modules without compromising on the heat transfer from the batteries to the fluid or risking a thermal runaway event spreading from one battery to another consecutive battery.
The disclosed system for battery thermal management comprising one or more battery case, one or more batteries, heat transfer fluid, fluid circulation device and so forth. In accordance with an embodiment, one or more batteries are at least partially submerged within a liquid contained within the one or more battery case.
The system comprises one or more fluid circulation device configured to circulate the heat transfer fluid through the one or more battery case containing one or more batteries that are at least partially submerged within the heat transfer fluid contained inside the one or more battery case. In an embodiment, the one or more fluid circulation device is selected from the group comprising at least one of a pump, blower, fan, compressor, internal ducts with orifices or their combinations. In another embodiment, the one or more fluid circulation device is configured to generate a swirl motion in the heat transfer fluid to transfer the heat from the one or more batteries to the heat transfer fluid, and thereby transfer the heat from the heat transfer fluid to the one or more battery case. In an embodiment, heat transfer fluids are commercially available that are designed for heat transfer applications which have boiling points appropriate to heat absorbing and further heat transferring applications. The heat transfer fluids employed herein have negligible toxicity (biologically inert), have no ozone depletion potential, have low greenhouse gas potential, are non-flammable, and have other mechanical properties favourable for said battery thermal management system.
In accordance with an embodiment, the system operates at atmospheric pressure and, thus, puts no additional mechanical stress on individual one or more batteries, and requires no additional mass or reinforcement of the one or more battery container that would be required as a pressure vessel. In another embodiment, the heat transfer fluid is circulated through the one or more batteries with minimal effort in order to ensure uniform temperature distribution and cooled with the one or more battery casing as a standard heat exchanger in order to keep the battery well within the desirable temperature range, thus extending the usable life of the battery.
In an embodiment, the present disclosure employs a dielectric heat transfer fluid for transferring the heat from the one or more batteries to the atmosphere. The heat transfer fluids are used in processes where cooling or heating is required to obtain and maintain a particular temperature. Furthermore, employing the dielectric heat transfer fluid cuts out oxygen supply to the one or more batteries, thereby providing protection against fires caused in case of short-circuits overcurrent, overvoltage, cell rupture and thermal runaway. Consequently, the one or more batteries are safely discharged to zero voltage during such events without occurrence of fire. In an embodiment, the chemistries that are used as heat transfer fluids are fully synthetic dielectric ester, Naphthenic based and Paraffinic based oils are used and can also be used up with a proper additive package.
According to an embodiment of the present disclosure, the system comprises one or more temperature sensors to determine the temperature of the one or more batteries at least partially submerged within the heat transfer fluid. The one or more temperature sensor involves sensing a temperature of one or more batteries. In accordance with the present disclosure as described herein, one or more batteries are at least partially submerged within a heat transfer fluid contained within the one or more battery case.
Furthermore, in an embodiment, the system comprises a processor configured to turn on the one or more fluid circulation devices when the temperature determined by the one or more temperature sensors of at least a battery from the one or more batteries exceeds a predetermined value. In an embodiment, the processor is configured to turn off the one or more fluid circulation devices when the temperature of all the batteries from the one or more batteries are below the predetermined value. In an embodiment, the processor comprises at least one microcontroller that sense the temperature of one or more batteries with the calibrated predetermined value.
In accordance with an embodiment of the present disclosure, the system comprises a processor that controls the stage- wise switching on/off the fluid circulation device. In another embodiment, the processor comprises a microcontroller that control the stage wise turning on/off the fluid circulation device fans based on temperature comparison of the one or more batteries with the predetermined threshold value of the one or more batteries. In an example, the one or more fluid circulation device is switched on by the processor when at least one temperature sensor detects value above the predetermined threshold value.
In accordance with an embodiment, the one or more fluid circulation device is configured to generate a flow in the heat transfer fluid to accelerate the transfer the heat from the one or more batteries to the heat transfer fluid, and further to accelerate the transfer of heat from the heat transfer fluid to the one or more battery case. In another embodiment, the one or more fluid circulation device comprises one or more fans internally attached to the one or more battery casing. In yet another embodiment, the one or more fluid circulation device comprises one or more (submerged) pumps internally fitted inside the one or more battery casing. Furthermore, in another embodiment, the one or more fans and/or one or more pumps are internally connected to the one or more battery casing. The system herein generates a swirl motion via one or more fluid circulation device to carry heat from one or more batteries to heat transfer fluid to casing and then to atmosphere via battery casing. Herein the present disclosure, the fluid circulation devices such as pumps, blowers, compressors and so forth are configured to provide internal circulation of heat transfer fluid through the one or more batteries so as transferring the heat from one or more batteries to the heat transfer fluids. In another embodiment, the one or more fluid circulation device is further configured to make the heat transfer fluids to flow across the higher temperature zones associated with the one or more batteries. In an embodiment, the processor analyses the temperature sensor data and identifies the one or more higher temperature zonesassociated with the one or more batteries and arranges the flow of heat transfer fluid in such a way that flow will occur majorly across the higher temperature zones associated with the one or more batteries.
In accordance with an embodiment, the processor works in conjunction with the one or more temperature sensors to identify the higher temperature zones associated with the one or more batteries. Beneficially, identifying the higher temperature zones associated with the one or more batteries and thereafter configuring the flow of heat transfer fluid majorly through those higher temperature zones results in increasing the efficiency of battery thermal management system. Furthermore, the power input required to operate the fluid circulation devices may also be reduced to great extent by employing the above-mentioned configuration.
According to an embodiment, the system comprises one or more temperature sensors that determines the temperature of one or more batteries. Furthermore, a processor is also described herein that analyses and compares the temperatures of one or more batteries with the calibrated temperature predetermined threshold value. In another embodiment, the processor further controls the stage-wise switching off of fluid circulation device, based on temperature comparison. In an example, the processor switches off the one or more fluid circulation device when all the temperature sensors detect temperature below the predetermined threshold value.
In a particular embodiment, the one or more fluid circulation device configures the flow of heat transfer fluids through the one or more batteries. The processor herein controls the one or more fluid circulation device to make the flow of the heat transfer fluid in a packetized form. Advantageously, flowing of the heat transfer fluids in a packetized form makes the system more efficient. The packetized form refers to providing only a certain amount of fluid across the one or more batteries in a certain interval of time. The fluids recurrently flow in packets in a predefined interval of time.
In a particular embodiment, the one or more heating elements are also disclosed that are at least partially submerged within the heat transfer fluid and are contained in one or more battery case, wherein the heat generated by the one or more heating elements are first transferred from the heating element to the heat transfer fluid and thereafter from the fluid to the one or more batteries inside the one or more battery casings.
The present disclosure also relates to an apparatus for battery thermal management system, wherein the apparatus comprises one or more battery case, one or more batteries configured to be at least partially submerged within a heat transfer fluid contained in the one or more battery case, one or more fluid circulation device configured to circulate the heat transfer fluid through the one or more batteries that is at least partially submerged within the heat transfer fluid contained inside the one or more battery case, wherein the one or more battery case is configured to transfer the heat from the heat transfer fluid contained inside the one or more battery case into the atmosphere. Furthermore, one or more temperature sensors are also provided, for determining the temperature of the one or more batteries at least partially submerged within the heat transfer fluid. The system comprises a processor that is configured to turn on the one or more fluid circulation device when the temperature of at least a battery from the one or more batteries exceeds a predetermined value.
In an embodiment, the one or more temperature sensor determines the temperature of the one or more batteries. The processor(s) compares the temperature of the one or more batteries with a predetermined maximum threshold value (e.g., this temperature may be a predefined maximum temperature specified by the manufacturer of the one or more batteries). If the processor(s) determines that the temperature of the one or more batteries is above the predetermined threshold temperature value, the processor(s) will command (e.g., by sending a command signal to) a cooling unit to be activated (e.g., turned on). In another embodiment, the cooling unit comprises one or more fluid circulating device. In yet another embodiment, the cooling unit employs a radiator-type structure. In some embodiments, the cooling unit also employs a fan to aid in the cooling process. In accordance with an embodiment of the present disclosure, the system comprises a fan type circulation of the battery thermal management system. Herein, the one or more fluid circulation device comprises of one or more fans or blowers. In a particular embodiment, the cooling unit comprises a fan internally mounted in the one or more battery casing. Employing one or more fans internally connected to the one or more battery casing leads to providing a compact structure. The one or more fans are structured in such a way that a flow (for example in the form of swirl motion) in the heat transfer fluid is generated to transfer the heat from the one or more batteries to the heat transfer fluid, and further transfer the heat from the heat transfer fluid to the one or more battery case. In yet another embodiment, the cooling unit comprises one or more fans externally mounted on the one or more battery casing. In accordance with the above embodiments described above, the number of fans depend on the battery size. Larger the battery size, more will be the number of fans.
According to an embodiment, the system comprises a channel type circulation system that further comprises one or more duct type fluid circulation device. Herein, the system comprises one or more pumps that facilitates in transferring the heat transfer fluid to the higher temperature zones of one or more batteries. The fluid circulation device according to this embodiment (in an example, the pump) takes in the heat transfer fluid via the fluid inlet and make the heat transfer fluid flow through the at least one duct. The one or more hotspots are determined by the processor by analysing the temperature readings of one or more temperature sensors. In an embodiment, the duct type circulation system comprises at least one duct that defines the path of circulation of the heat transfer fluids. Said at least one duct comprises at least one duct outlet that spray or transfer the heat transfer fluid to the determined higher temperature zones of the one or more batteries. In accordance with the above embodiments described above, the number of pumps depend on the battery size. Larger the battery size, more will be the number of pumps.
Furthermore, in another embodiment, the one or more battery case comprises a plurality of fins or any other geometric structure on its surface for facilitating the heat transfer from one or more batteries to the atmosphere. The heat generated from the one or more batteries is transferred from the one or more batteries to the heat transfer fluid. In an example, the heat transfer fluid absorbs the heat from the one or more batteries. The heat further transfers from the heat transfer fluid to the atmosphere via the battery casing.
In an embodiment, the processor is configured to turn off the one or more fluid circulation device when the temperature of all the batteries from the one or more batteries are below the predetermined value.
In another embodiment, the one or more battery case comprises a plurality of fins or other geometric heat transfer mediums on its surface to facilitate the transferring of heat into the atmosphere.
The present disclosure also relates to the method for battery thermal management system, wherein the method comprises determining via one or more sensors, temperature of one or more batteries, wherein the one or more batteries are at least partially submerged within a heat transfer fluid contained in one or more battery case. The method further comprises determining via a processor, if the temperature of at least one of a battery from the one or more batteries exceeds a predetermined value and further commanding via the processor, to turn on one or more fluid circulation device.
In accordance with an embodiment of the present disclosure, the system comprises one or more temperature sensors, one or more fluid circulation device, a processor, dielectric fluid, one or more battery pack including cells, bus-bars and connectors, couplers and wires. The processor includes a microcontroller that determines the temperature of one or more submerged one or more batteries within the one or more battery casing. The processor is configured to analyse and compare the sensed temperature with the calibrated predetermined temperature threshold value. Furthermore, the processor or microcontroller controls the stage wise turning on of the one or more fluid circulation device based on temperature comparison. In an example, the processor turns on the one or more fluid circulation device when one or more temperature sensor detects value above a certain predetermined threshold value. After turning on the one or more fluid circulation device, the heat transfer fluid inside the battery casing carry heat from one or more batteries to heat transfer fluid and further to casing and thereafter to the atmosphere via battery casing as the one or more battery casing acts as a heat exchanger or a heat transfer interface.
In a further embodiment, the processor or microcontroller analyses and compares the sensed temperature of one or more batteries with the calibrated predetermined temperature threshold values. Based on the comparison of the sensed temperature with the predetermined temperature threshold value, the processor or microcontroller controls the stage wise turning off of the one or more fluid circulation device. In an example, the one or more fluid circulation device is turned off when the temperature of all the temperature sensors in the system are below a certain predetermined temperature threshold value.
Various embodiments and variants disclosed above apply mutatis mutandis to the method, system and apparatus.
DESCRIPTION OF THE DRAWINGS Referring to Fig. 1, there is shown a schematic illustration of a battery thermal management system 100, in accordance with an embodiment of the present disclosure. The system 100 comprises one or more batteries 102, one or more battery casing 104, a battery management system 106, fluid circulation device 108, and a heat transfer fluid 110. The system further comprises a bottom mounting plate 112 configured to support the one or more battery casing. Herein this embodiment, the one or more fluid circulation device is selected from at least one of fan and/or blower that are arranged either internally and/or externally to the one or more battery casing 104. The battery management system 106 comprises a processor that is configured to monitor and/or control the overall operations of battery management system. The processor configured to turn on the one or more fluid circulation device when the temperature determined by the one or more temperature sensors of at least a battery from the one or more batteries exceeds a predetermined value. The heat transfer fluid flows across the one or more batteries 102 in the battery casing 104 to absorb heat from the one or more batteries 102. The heat is being transferred from the one or more batteries to the heat transfer fluid and thereafter from the heat transfer fluid to the atmosphere via the battery casing 104. In another embodiment, the processor is configured to turn off the one or more fluid circulation device when the temperature of all the batteries from the one or more batteries are below the predetermined value. In an embodiment, the processor comprises at least one microcontroller that sense the temperature of one or more batteries with the calibrated predetermined value.
Referring to Fig. 2a, there is shown a schematic illustration of a battery thermal management system 200, in accordance with another embodiment of the present disclosure. Fig. 2b shows the schematic illustration of a pump and channel assembly 250 in accordance with an embodiment of the present disclosure. The system 200 comprises one or more batteries 202, one or more battery casing 204, a battery management system 206, fluid circulation device 208, and heat transfer fluid 210. The system further comprises a bottom mounting plate 212 configured to support the one or more battery casing. Herein this embodiment, the one or more fluid circulation device is selected from the at least one pump, wherein the heat transfer fluid 210 is being pumped by the one or more pumps in the one or more channels or ducts or tubes 216. The one or more ducts 216 comprises one or more duct outlet 218 that spray or outlet the heat transfer fluid to the one or more hotspot associated with the one or more batteries. In an embodiment, the one or more duct outlet 218 sprays or outlets the heat transfer fluid to the over the one or more batteries and/or across the one or more batteries. The battery management system 206 further comprises a processor that is configured to monitor the operations of whole battery management system. The processor configured to turn on the one or more fluid circulation device when the temperature determined by the one or more temperature sensors of at least a battery from the one or more batteries exceeds a predetermined value. In another embodiment, the processor is configured to turn off the one or more fluid circulation device when the temperature of all the batteries from the one or more batteries are below the predetermined value. In an embodiment, the processor comprises at least one microcontroller that sense the temperature of one or more batteries with the calibrated predetermined value.
Referring to FIG. 3, there is shown a schematic illustration 300 of a surface of one or more battery casing, in accordance with an embodiment of the present disclosure. The surface 302 comprises one or more heat transferrable mediums 304 for facilitating heat transfer from the heat transfer fluid to the atmosphere. In an embodiment, the heat transfer medium comprises a plurality of fins or other heat transfer surfaces for providing heat transfer surface from the heat transfer fluid to the atmosphere via one or more battery casing. In another embodiment, the plurality of fins comprising at least one of Straight fins, Radial fins, Annular fins, and Pin fins.
Referring to FIG. 4, there is shown a schematic illustration of a flow diagram of a method 400 for the operations of battery thermal management system, in accordance with an embodiment of the present disclosure. At a step 402, the method comprises determining via one or more sensors, temperature of one or more batteries, wherein the one or more batteries are at least partially submerged within a heat transfer fluid contained in one or more battery case. At step 404, the method comprises determining via a processor, if the temperature of at least one of a battery from the one or more batteries exceeds a predetermined value. Furthermore, at step 406, the method comprising commanding via the processor, to turn on one or more fluid circulation device.
Modifications to embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as “including”, “comprising”, “incorporating”, “have”, “is” used to describe and claim the present disclosure are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural where appropriate.

Claims

We Claim:
1. A system for battery thermal management, wherein the system comprises: one or more battery case; one or more batteries configured to be at least partially submerged within a heat transfer fluid contained in the one or more battery case; and one or more fluid circulation device configured to circulate the heat transfer fluid through the one or more battery case containing one or more batteries that are at least partially submerged within the heat transfer fluid contained inside the one or more battery case, wherein the one or more battery case is configured to transfer the heat from the heat transfer fluid contained inside the one or more battery case into the atmosphere.
2. The system as claimed in claim 1, wherein the one or more fluid circulation device is selected from the group comprising at least one of a pump, blower, fan, compressor or their combinations.
3. The system as claimed in claim 1, wherein the one or more fluid circulation device is configured to generate a flow in the heat transfer fluid to transfer the heat from the one or more batteries to the heat transfer fluid, and further transfer the heat from the heat transfer fluid to the one or more battery case.
4. The system as claimed in claim 1, wherein the one or more battery case acts as a heat exchanger that transfers the heat from the heat transfer fluid contained inside the one or more battery case into the atmosphere.
5. The system as claimed in claim 4, wherein the one or more battery case comprises a plurality of heat transfer mediums on its surface to facilitate the transferring of heat into the atmosphere.
6. The system as claimed in claim 1, wherein the heat transfer fluid is selected from a dielectric cooling heat transfer fluid to cut off air supply to the one or more batteries in an event of fire hazard.
7. The system as claimed in claim 1, wherein the system comprises one or more temperature sensors to determine the temperature of the one or more batteries at least partially submerged within the heat transfer fluid.
8. The system as claimed in claim 1, wherein the system comprises a processor configured to turn on the one or more fluid circulation device when the temperature determined by the one or more temperature sensors of at least a battery from the one or more batteries exceeds a predetermined value.
9. The system as claimed in claim 8, wherein the processor is configured to turn off the one or more fluid circulation device when the temperature of all the batteries from the one or more batteries are below the predetermined value.
10. The system as claimed in claim 1, wherein the one or more heating elements at least partially submerged within the heat transfer fluid are contained in one or more battery case, wherein the heat generated by the one or more heating elements is first transferred from the heating element to the heat transfer fluid and thereafter from the fluid to the one or more batteries inside the one or more battery casings.
11. An apparatus for battery thermal management, wherein the apparatus comprises: one or more battery case; one or more batteries configured to be at least partially submerged within a heat transfer fluid contained in the one or more battery case; one or more fluid circulation device configured to circulate the heat transfer fluid through the one or more batteries that is at least partially submerged within the heat transfer fluid contained inside the one or more battery case, wherein the one or more battery case is configured to transfer the heat from the heat transfer fluid contained inside the one or more battery case into the atmosphere; one or more temperature sensors for determining the temperature of the one or more batteries at least partially submerged within the heat transfer fluid; and a processor that is configured to: turn on the one or more fluid circulation device when the temperature of at least a battery from the one or more batteries exceeds a predetermined value.
12. The apparatus as claimed in claim 11, wherein the processor is configured to turn off the one or more fluid circulation device when the temperature of all the batteries from the one or more batteries, are below the predetermined value.
13. The apparatus as claimed in claim 11, wherein the one or more fluid circulation device is selected from the group comprising at least one of a pump, blower, fan, compressor or their combinations.
14. The apparatus as claimed in claim 11, wherein the one or more fluid circulation device is configured to generate a flow in the heat transfer fluid to transfer the heat from the one or more batteries to the heat transfer fluid, and further transfer the heat from the heat transfer fluid to the one or more battery case.
15. The apparatus as claimed in claim 11, wherein the one or more battery case acts as a heat exchanger that transfers the heat from the heat transfer fluid contained inside the one or more battery case into the atmosphere.
16. The apparatus as claimed in claim 11, wherein the one or more battery case comprises a plurality of heat transfer mediums on its surface to facilitate the transferring of heat into the atmosphere.
17. The apparatus as claimed in claim 11, wherein the heat transfer fluid is selected from a dielectric cooling heat transfer fluid to cut off air supply to the one or more batteries in an event of fire hazard.
18. The apparatus as claimed in claim 11, wherein the one or more heating elements at least partially submerged within the heat transfer fluid, are contained in one or more battery case, wherein the heat generated by the one or more heating elements is first transferred from the heating element to the heat transfer fluid and thereafter from the heat transfer fluid to the one or more batteries inside the one or more battery casing.
19. A method for battery thermal management, wherein the method comprises: determining via one or more sensors, temperature of one or more batteries, wherein the one or more batteries are at least partially submerged within a heat transfer fluid contained in one or more battery case; determining via a processor, if the temperature of at least one of a battery from the one or more batteries exceeds a predetermined value; and commanding via the processor, to turn on one or more fluid circulation device.
20. The method as claimed in claim 19, wherein the method comprises determining via a processor if the temperature of at least one of a battery from the one or more batteries is below a predetermined value.
21. The method as claimed in claim 20, wherein the method comprises commanding via the processor to turn off the one or more fluid circulation device.
PCT/IB2023/052348 2022-03-11 2023-03-11 System and method for battery thermal management WO2023170661A1 (en)

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Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20210066768A1 (en) * 2019-08-30 2021-03-04 Baidu Usa Llc Battery thermal management system with passive battery pack cooling

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20210066768A1 (en) * 2019-08-30 2021-03-04 Baidu Usa Llc Battery thermal management system with passive battery pack cooling

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