Thermal management module system of new energy automobile battery and control method of thermal management module system

Abstract

The invention belongs to the technical field of new energy automobile thermal management, and particularly relates to a thermal management module system of a new energy automobile battery and a control method thereof. The method comprises the following steps: determining a working temperature range of a battery pack, selecting a proper phase-change material, arranging a sensor in the phase-change material to monitor temperature change, adjusting a contact area between the phase-change material and a battery based on sensor data, changing the contact area to control a heat absorption rate, and adjusting an internal structure layout of the phase-change material by utilizing the heat absorption rate. And optimizing the heat release rate of the phase-change material according to the structural layout, and finally maintaining the stable working temperature of the battery pack according to the heat release rate. According to the method, the heat absorption and release rate can be accurately controlled, the influence of local temperature fluctuation on the service life and the performance of the battery is effectively avoided, the stability and the reliability of the battery pack in rapid charge-discharge circulation are remarkably improved, meanwhile, the safety of the system is improved, the service life of the system is prolonged, and the complexity and the maintenance cost are reduced.

Description

Technical Field

[0001] The present invention belongs to the technical field of new energy vehicle thermal management, and particularly relates to a thermal management module system for new energy vehicle batteries and its control method. Background Technique

[0002] In the field of new energy vehicles, the thermal management of battery packs is one of the key factors to ensure their efficient operation and extended service life. Existing thermal management systems mainly use air cooling, liquid cooling, or direct contact cooling methods to control the battery temperature. Although these methods can maintain the battery operating temperature to a certain extent, during rapid charging and discharging processes, the heat generated by the battery is relatively large, and traditional cooling methods often struggle to quickly and effectively regulate the temperature, resulting in local temperature fluctuations, which in turn affect the battery's performance and lifespan.

[0003] General solutions of the prior art: Air cooling: Air is introduced around the battery pack through a fan or natural convection for cooling. This method has a simple structure and low cost, but the cooling efficiency is relatively low, especially in high-load operating conditions.

[0004] Liquid cooling: A coolant circulation system is used to absorb the heat generated by the battery. Although the cooling effect is better than air cooling, the system is complex, increasing the weight and maintenance cost.

[0005] Direct contact cooling: A heat-conducting material is used to directly contact the battery surface for heat dissipation. This method can effectively improve the heat dissipation efficiency, but the material selection and layout design are relatively complex, and there is a problem of uneven heat conduction.

[0006] Although the above methods can alleviate the problem of excessive battery temperature to a certain extent, in the design of using phase change materials (PCM) for battery thermal management, how to precisely control the heat absorption and release rates during the phase change process to ensure that the battery pack maintains a stable operating temperature during rapid charging and discharging cycles, while avoiding the negative impact on battery life and performance caused by local temperature fluctuations due to phase change hysteresis effects, remains an urgent problem to be solved. Summary of the Invention

[0007] The purpose of the present invention is to provide a thermal management module system for new energy vehicle batteries and its control method, which can precisely control the heat absorption and release rates, effectively avoid the influence of local temperature fluctuations on battery life and performance, and thus significantly improve the stability and reliability of the battery pack during rapid charging and discharging cycles, so as to solve the problems raised in the above background technique.

[0008] To achieve the above object, on the one hand, the present invention proposes a thermal management control method for new energy vehicle batteries, including the following steps: Determine the operating temperature range of the battery pack, measure the initial temperature values of the battery pack under different working conditions, select phase change materials according to the operating temperature range, conduct thermal conductivity tests on the phase change materials, and calculate the thermal conductivity coefficients of each material; arrange sensors in the phase change materials to monitor temperature changes, collect the temperature data monitored by the sensors, adjust the contact area between the phase change material and the battery based on the temperature data of the sensors; control the heat absorption rate by changing the contact area, calculate the current heat absorption rate based on the contact area and real-time temperature data, and adjust the internal structure layout of the phase change material using the heat absorption rate; optimize the heat release rate of the phase change material according to the structure layout, and maintain the stable operating temperature of the battery pack based on the heat release rate.

[0009] Preferably, the determination of the operating temperature range of the battery pack includes the following steps: Measure the initial temperature values of the battery pack under different working conditions; Based on the initial temperature values, calculate the highest and lowest operating temperature limits; wherein, the highest operating temperature limit is the initial temperature value plus the maximum temperature difference, and the lowest operating temperature limit is the initial temperature value minus the minimum temperature difference; According to the highest and lowest operating temperature limits, divide into multiple temperature intervals, and the width of each temperature interval is determined by the highest and lowest operating temperature limits; For each temperature interval, set the phase change trigger conditions for the corresponding phase change material. When the detected battery temperature reaches the upper or lower limit of the temperature interval, start the phase change process of the corresponding phase change material to adjust the battery temperature back into the target interval.

[0010] Preferably, the selection of phase change materials according to the operating temperature range includes the following steps: Determine the average temperature value within the operating temperature range, and the average temperature value is the average of the highest operating temperature limit and the lowest operating temperature limit; Based on the average temperature value, screen out the candidate phase change materials that meet this temperature range, and the screening condition is that the phase change temperature of the candidate phase change materials is within the range of the average temperature value; Conduct thermal conductivity tests on the candidate phase change materials and calculate the thermal conductivity coefficients of each material; According to the thermal conductivity coefficients, select the phase change material with the highest thermal conductivity as the final choice. When multiple candidate phase change materials have the same highest thermal conductivity coefficient, select the material with the smallest density to optimize the overall weight of the battery pack.

[0011] Preferably, arranging sensors in the phase change material to monitor temperature changes includes the following steps: Determine the geometric shape and size of the phase change material; Based on the geometry and dimensions, a plurality of monitoring points are evenly distributed inside the phase change material, and the number of monitoring points is determined according to the volume of the phase change material and the volume covered by a single monitoring point; A temperature sensor is installed at each monitoring point, and the initial temperature value is recorded. The spacing between the temperature sensors is determined according to the length of the longest side of the phase change material and the number of monitoring points; The temperature data is transmitted to the central control system through the data line connecting all the temperature sensors.

[0012] Preferably, the adjusting the contact area between the phase change material and the battery based on the sensor data includes the following steps: Collect the temperature data monitored by the sensor, and the temperature data includes the real-time temperature value of each monitoring point; Calculate the average temperature of the contact surface between the phase change material and the battery according to the temperature data, and the average temperature is the average of the temperature values of each monitoring point; Compare the average temperature with the set target temperature range; if the average temperature is higher than the upper limit of the target temperature, increase the contact area between the phase change material and the battery; if the average temperature is lower than the lower limit of the target temperature, reduce the contact area between the phase change material and the battery; Change the contact area by moving or adjusting the position and layout of the phase change material.

[0013] Preferably, the controlling the heat absorption rate by changing the contact area includes the following steps: Measure the current contact area between the phase change material and the battery, and the contact area is the projected area of the phase change material on the battery surface; Calculate the current heat absorption rate according to the contact area and the real-time temperature data; Compare the heat absorption rate with the set target absorption rate; if the heat absorption rate is lower than the target absorption rate, increase the contact area between the phase change material and the battery; if the heat absorption rate is higher than the target absorption rate, reduce the contact area between the phase change material and the battery; Adjust the position or layout of the phase change material to change the contact area.

[0014] Preferably, the adjusting the internal structure layout of the phase change material by using the heat absorption rate includes the following steps: Determine the current working state of the phase change material according to the heat absorption rate; if the heat absorption rate is high, it indicates that the phase change material is in a rapid heat absorption state; if the heat absorption rate is low, it indicates that the phase change material is in a slow heat absorption or stable state; Adjust the heat conduction path inside the phase change material based on the heat absorption rate; Redistribute the reinforcing material inside the phase change material to optimize the heat conduction path. When the distribution density increases, the reinforcing material concentrates more in the high-temperature region, and vice versa, it concentrates in the low-temperature region; Adjust the overall layout of the phase change material according to the new distribution of the reinforcing material.

[0015] Preferably, optimizing the heat release rate of the phase change material according to the above structural layout includes the following steps: Measure the temperature distribution inside the current phase change material, and the temperature distribution is the temperature values of each monitoring point; Calculate the current heat release rate of the phase change material based on the temperature distribution and the structural layout; Compare the heat release rate with the set target release rate; if the heat release rate is lower than the target release rate, adjust the distribution density of the reinforcing material inside the phase change material; if the heat release rate is higher than the target release rate, reduce the distribution density of the reinforcing material inside the phase change material; Rearrange the heat conduction path inside the phase change material according to the new distribution density.

[0016] Preferably, maintaining the stable operating temperature of the battery pack according to the heat release rate includes the following steps: Monitor the heat release rate of the current phase change material; Calculate the actual temperature change of the battery pack according to the heat release rate; Compare the actual temperature change with the set target temperature range; if the actual temperature change exceeds the upper limit of the target temperature range, reduce the heat release rate of the phase change material; if the actual temperature change is lower than the lower limit of the target temperature range, increase the heat release rate of the phase change material; Adjust the heat release rate by adjusting the distribution of the reinforcing material and the heat conduction path inside the phase change material to keep the operating temperature of the battery pack within the target range.

[0017] On the other hand, the present invention proposes a thermal management module system applicable to new energy vehicle batteries, including: An operating temperature determination module for determining the operating temperature range of the battery pack; A phase change material selection module for selecting a phase change material according to the operating temperature range; A sensor arrangement and monitoring module for arranging sensors in the phase change material to monitor temperature changes; A contact area adjustment module for adjusting the contact area between the phase change material and the battery based on the sensor data; A heat absorption rate control module for controlling the heat absorption rate by changing the contact area; The internal structure layout adjustment module is used to adjust the internal structure layout of the phase change material by using the heat absorption rate; The heat release rate optimization module is used to optimize the heat release rate of the phase change material according to the structure layout; The battery pack temperature stability maintenance module is used to maintain the stable operating temperature of the battery pack according to the heat release rate.

[0018] Technical effects and advantages of the present invention: A thermal management module system and its control method for a new energy vehicle battery proposed by the present invention have the following advantages compared with the prior art: The present invention determines the operating temperature range of the battery pack, selects a suitable phase change material, arranges sensors in the phase change material to monitor temperature changes, adjusts the contact area between the phase change material and the battery based on sensor data, controls the heat absorption rate by changing the contact area, adjusts the internal structure layout of the phase change material by using the heat absorption rate, optimizes the heat release rate of the phase change material according to the structure layout, and finally maintains the stable operating temperature of the battery pack according to the heat release rate. This method can accurately control the heat absorption and release rates, effectively avoid the influence of local temperature fluctuations on the battery life and performance, significantly improve the stability and reliability of the battery pack during rapid charge and discharge cycles, simultaneously enhance the safety and service life of the system, and reduce the complexity and maintenance cost. Description of the drawings

[0019] Figure 1 is a flowchart of the thermal management control method for a new energy vehicle battery applicable to the present invention; Figure 2 is a block diagram of the thermal management module system for a new energy vehicle battery applicable to the present invention. Detailed implementation manners

[0020] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. The specific embodiments described herein are only used to explain the present invention, and are not used to limit the present invention. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0021] The present invention provides a thermal management control method for a new energy vehicle battery as Figure 1 shown, including the following steps: I. Determine the operating temperature range of the battery pack; including the following steps: Measure the initial temperature value of the battery pack under different working conditions; By measuring the initial temperature value of the battery pack under different working conditions (such as charging, discharging, standing still, etc.), the temperature change of the battery pack during actual use can be understood, providing basic data for subsequent temperature management.

[0022] Based on the initial temperature value, calculate the upper and lower working temperature limits; Among them, the upper working temperature limit = initial temperature value + ΔT_max (maximum temperature difference), the lower working temperature limit = initial temperature value - ΔT_min (minimum temperature difference); By setting the upper and lower working temperature limits, ensure that the battery pack operates within a safe range. ΔT_max and ΔT_min represent the maximum temperature rise and maximum temperature drop allowed for the battery pack respectively.

[0023] According to the upper and lower working temperature limits, divide into multiple temperature intervals; The width of each temperature interval is (upper working temperature limit - lower working temperature limit) / N (number of temperature intervals), N is a positive integer; Divide the entire working temperature range into multiple small temperature intervals to facilitate more precise control of the phase change process of the phase change material (PCM) and ensure that the battery temperature is always in the best working state.

[0024] For each temperature interval, set the corresponding phase change trigger condition of the phase change material; When the detected battery temperature reaches the upper or lower limit of the temperature interval, start the phase change process of the corresponding phase change material to adjust the battery temperature back into the target interval.

[0025] Suppose the measurement results of the initial temperature value of a new energy vehicle battery pack under different working conditions are as follows: When standing still: 25°C; When charging: 30°C; When discharging: 35°C; Measure the initial temperature value of the battery pack under different working conditions: When standing still: 25°C; When charging: 30°C; When discharging: 35°C; Based on the initial temperature value, calculate the upper and lower working temperature limits: Suppose ΔT_max = 10°C, ΔT_min = 5°C; For standing still: upper working temperature limit = 25°C + 10°C = 35°C, lower working temperature limit = 25°C - 5°C = 20°C; For charging: upper working temperature limit = 30°C + 10°C = 40°C, lower working temperature limit = 30°C - 5°C = 25°C; For discharging: The upper working temperature limit = 35°C + 10°C = 45°C, and the lower working temperature limit = 35°C - 5°C = 30°C; According to the upper and lower working temperature limits, divide into multiple temperature intervals: Assume N = 5 temperature intervals are selected; For standing still: The width of each temperature interval = (35°C - 20°C) / 5 = 3°C; The temperature intervals are respectively: 20°C - 23°C, 23°C - 26°C, 26°C - 29°C, 29°C - 32°C, 32°C - 35°C; For charging: The width of each temperature interval = (40°C - 25°C) / 5 = 3°C; The temperature intervals are respectively: 25°C - 28°C, 28°C - 31°C, 31°C - 34°C, 34°C - 37°C, 37°C - 40°C; For discharging: The width of each temperature interval = (45°C - 30°C) / 5 = 3°C; The temperature intervals are respectively: 30°C - 33°C, 33°C - 36°C, 36°C - 39°C, 39°C - 42°C, 42°C - 45°C; For each temperature interval, set the phase change trigger condition of the corresponding phase change material: When the detected battery temperature reaches the upper or lower limit of a certain temperature interval, start the phase change process of the corresponding phase change material.

[0026] For example, when standing still, if the battery temperature rises to 32°C, start the phase change process of the phase change material to absorb the excess heat and reduce the battery temperature below 29°C; conversely, if the battery temperature drops to 23°C, start the phase change process of the phase change material to release heat and raise the battery temperature above 26°C.

[0027] II. Select phase change materials according to the working temperature range; including the following steps: Determine the average temperature value within the working temperature range; The average temperature value = (upper working temperature limit + lower working temperature limit) / 2; By calculating the average temperature value of the working temperature range, a reference temperature can be provided for subsequent screening of suitable phase change materials to ensure that the selected material can work effectively within this temperature range.

[0028] Based on the average temperature value, screen out the candidate phase change materials that meet this temperature range; The screening condition is that the phase change temperature of the candidate phase change material is within the average temperature value ± ΔT_range (phase change temperature range); ΔT_range is an allowable temperature fluctuation range to ensure that the selected material can work stably under actual working conditions.

[0029] Perform thermal conductivity tests on the candidate phase change materials and calculate the thermal conductivity coefficient of each material; Thermal conductivity coefficient = heat conduction amount of the material / (material thickness × temperature difference), where the temperature difference is a fixed value; Through the thermal conductivity test, evaluate the heat conduction performance of each candidate material. The higher the thermal conductivity coefficient, the better the heat conduction efficiency of the material, and it can more effectively regulate the temperature of the battery pack.

[0030] Based on the thermal conductivity coefficient, select the phase change material with the highest thermal conductivity as the final choice; When multiple candidate phase change materials have the same highest thermal conductivity coefficient, select the material with the smallest density to optimize the overall weight of the battery pack.

[0031] Suppose the operating temperature range of a new energy vehicle battery pack is as follows: Highest operating temperature limit = 40°C; Lowest operating temperature limit = 30°C; Determine the average temperature value within the operating temperature range: Average temperature value = (40°C + 30°C) / 2 = 35°C; Based on the average temperature value, screen out the candidate phase change materials that meet this temperature range: Suppose ΔT_range = 5°C; The screening condition is that the phase change temperature of the candidate phase change material is within the range of 35°C ± 5°C, that is, 30°C to 40°C; Suppose there are the following candidate phase change materials: Material A: Phase change temperature 32°C; Material B: Phase change temperature 35°C; Material C: Phase change temperature 38°C; Perform thermal conductivity tests on the candidate phase change materials and calculate the thermal conductivity coefficient of each material: Suppose the material thickness is 1 cm and the temperature difference is 10°C; Material A: Heat conduction amount is 20 W, thermal conductivity coefficient = 20 W / (1 cm × 10°C) = 2 W / (cm·°C); Material B: Heat conduction amount is 25 W, thermal conductivity coefficient = 25 W / (1 cm × 10°C) = 2.5 W / (cm·°C); Material C: Heat conduction amount is 20 W, thermal conductivity coefficient = 20 W / (1 cm × 10°C) = 2 W / (cm·°C); Based on the thermal conductivity coefficient, select the phase change material with the highest thermal conductivity as the final choice: Among the above three materials, the thermal conductivity coefficient of Material B is the highest, which is 2.5 W / (cm·°C), so Material B is selected.

[0032] If the thermal conductivity coefficients of Material B and Material C are the same (e.g., both are 2 W / (cm·°C)), then further compare their densities: The density of Material B is 1.5 g / cm³; The density of Material C is 1.2 g / cm³; In this case, select Material C with the lowest density to optimize the overall weight of the battery pack.

[0033] Through the above steps, this method can accurately select the phase change material suitable for the operating temperature range of the battery pack. First, calculate the average temperature value of the operating temperature range, and screen out the candidate phase change materials that meet the requirements based on this value. Then, through thermal conductivity testing, select the material with the highest thermal conductivity to ensure the best thermal management effect. If the thermal conductivities of multiple materials are the same, select the material with the lowest density to reduce the overall weight of the battery pack, thereby improving the energy efficiency and safety of the vehicle.

[0034] III. Arrange sensors in the phase change material to monitor temperature changes; including the following steps: Determine the geometry and size of the phase change material; the geometry can be plate-shaped, block-shaped or granular, and the size is set according to the actual needs of the battery pack; the appropriate geometry and size can ensure good contact between the PCM and the battery pack, thereby improving the thermal management efficiency.

[0035] Based on the geometry and size, evenly distribute multiple monitoring points inside the phase change material; the number of monitoring points = volume of the phase change material / volume covered by a single monitoring point, and the volume covered by a single monitoring point is set according to the thermal diffusion characteristics of the phase change material; by calculating and evenly distributing the monitoring points, comprehensive monitoring of the internal temperature change of the PCM can be achieved, ensuring that temperature fluctuations can be detected in a timely manner at any position and corresponding thermal management measures can be taken.

[0036] Install temperature sensors at each monitoring point and record the initial temperature value; the spacing between temperature sensors = length of the longest side of the phase change material / (cube root of the number of monitoring points); reasonably set the spacing between temperature sensors to ensure the accuracy and reliability of temperature monitoring. Recording the initial temperature value provides reference data for subsequent temperature change analysis.

[0037] Transfer the temperature data to the central control system by connecting the data lines of all temperature sensors; the central control system calculates the temperature difference according to the formula ΔT_sens = T_max - T_min, where T_max and T_min are the highest and lowest temperature values read by all sensors respectively; when ΔT_sens exceeds the preset threshold, initiate corresponding thermal management measures to adjust the working state of the phase change material. Monitor the temperature change inside the PCM in real time through the central control system and calculate the temperature difference. When the temperature difference exceeds the preset threshold, the system can promptly initiate corresponding thermal management measures, adjust the working state of the PCM, and ensure that the battery pack operates within the optimal temperature range.

[0038] Suppose the phase change material (PCM) used in the battery pack of a new energy vehicle is as follows: Geometric shape: plate-like; Dimensions: length 20 cm, width 15 cm, height 5 cm; PCM volume = 20 cm × 15 cm × 5 cm = 1500 cm³; Volume covered by a single monitoring point = 100 cm³ (set according to the heat diffusion characteristics of the PCM); Determine the geometric shape and dimensions of the phase change material: The geometric shape of the PCM is plate-like, and the dimensions are 20 cm × 15 cm × 5 cm.

[0039] Based on the geometric shape and dimensions, evenly distribute multiple monitoring points inside the phase change material: Number of monitoring points = PCM volume / volume covered by a single monitoring point = 1500 cm³ / 100 cm³ = 15 monitoring points; the monitoring points are evenly distributed inside the PCM to ensure full coverage.

[0040] Install temperature sensors at each monitoring point and record the initial temperature value: Spacing between temperature sensors = length of the longest side of the PCM / cube root of the number of monitoring points = 20 cm / (15^(1 / 3)) ≈ 8.11 cm; install 15 temperature sensors and record the initial temperature value, for example, the initial temperature value is 30°C.

[0041] Transfer the temperature data to the central control system by connecting the data lines of all temperature sensors: The central control system calculates the temperature difference according to the formula ΔT_sens = T_max - T_min.

[0042] Suppose at a certain moment, the temperature values read by each sensor are as follows: Sensor 1: 31°C; Sensor 2: 30°C; Sensor 3: 32°C; ... Sensor 15: 33°C; Then T_max = 33°C, T_min = 30°C; ΔT_sens = 33°C - 30°C = 3°C; If the preset temperature difference threshold is 2°C, then ΔT_sens exceeds the preset threshold, and corresponding thermal management measures are initiated, such as adjusting the working state of the PCM to reduce the temperature difference.

[0043] Through the above steps, this method can accurately arrange temperature sensors in the phase change material to achieve real-time monitoring of the internal temperature change of the PCM. First, determine the geometry and size of the PCM, then evenly distribute the monitoring points according to its volume and thermal diffusion characteristics, install temperature sensors at each monitoring point, and record the initial temperature value. Finally, the central control system calculates the temperature difference in real time, and when the temperature difference exceeds the preset threshold, corresponding thermal management measures are initiated to ensure that the battery pack operates within the optimal temperature range.

[0044] In the above embodiment, the Texas Instruments TMP117 digital temperature sensor is selected. The following is its detailed application description: Determine the geometry and size of the phase change material: The geometry of the PCM is plate-shaped, with dimensions of 20 cm × 15 cm × 5 cm.

[0045] Based on the geometry and size, evenly distribute multiple monitoring points inside the phase change material: Number of monitoring points = PCM volume / Volume covered by a single monitoring point = 1500 cm³ / 100 cm³ = 15 monitoring points; The monitoring points are evenly distributed inside the PCM to ensure full coverage.

[0046] Install temperature sensors at each monitoring point and record the initial temperature value: Install 15 TMP117 temperature sensors and record the initial temperature value, for example, the initial temperature value is 30°C. The TMP117 is connected to the central control system through the I²C interface, and the data transmission is stable and highly accurate.

[0047] Transmit the temperature data to the central control system through the data lines connecting all the temperature sensors: The central control system calculates the temperature difference according to the formula ΔT_sens = T_max - T_min.

[0048] Suppose at a certain moment, the temperature values read by each sensor are as follows: Sensor 1: 31°C; Sensor 2: 30°C; Sensor 3: 32°C; ... Sensor 15: 33°C; Then T_max = 33°C and T_min = 30°C; ΔT_sens = 33°C - 30°C = 3°C; If the preset temperature difference threshold is 2°C, then ΔT_sens exceeds the preset threshold, and corresponding thermal management measures are initiated, such as adjusting the working state of the PCM to reduce the temperature difference.

[0049] By selecting Texas Instruments TMP117, high-precision monitoring of the internal temperature change of the PCM can be achieved. TMP117 has the advantages of high precision, low power consumption, and a digital interface, and is particularly suitable for the thermal management system of new energy vehicle battery packs.

[0050] IV. Adjust the contact area between the phase change material and the battery based on sensor data; including the following steps: Collect the temperature data monitored by the sensor; the temperature data includes the real-time temperature values of each monitoring point; by collecting the real-time temperature values of each monitoring point, the temperature distribution inside the phase change material (PCM) and the battery pack can be comprehensively understood.

[0051] Calculate the average temperature of the contact surface between the phase change material and the battery according to the temperature data; the average temperature = (T_1 + T_2 +... + T_n) / n, where T_1 to T_n are the temperature values of each monitoring point, and n is the number of monitoring points; by calculating the average temperature, the heat exchange state between the PCM and the battery can be accurately evaluated, and based on this, it can be determined whether the contact area between the PCM and the battery needs to be adjusted.

[0052] Compare the average temperature with the set target temperature range; if the average temperature is higher than the target temperature upper limit, increase the contact area between the phase change material and the battery; if the average temperature is lower than the target temperature lower limit, reduce the contact area between the phase change material and the battery; Change the contact area by moving or adjusting the position and layout of the phase change material; the change in contact area = k_contact × (average temperature - target temperature), where k_contact is the contact area adjustment coefficient used to determine the amplitude of each adjustment. By adjusting the contact area between the PCM and the battery, the heat transfer rate can be effectively controlled, ensuring that the PCM can absorb or release heat in the best state and maintaining the working temperature of the battery pack within the target range.

[0053] Suppose a new energy vehicle battery pack and its phase change material (PCM) are as follows: Number of monitoring points: 15; Set target temperature range: 30°C to 35°C; Initial monitoring point temperature values: [32°C, 31°C, 33°C, 34°C, 32°C, 31°C, 30°C, 33°C, 34°C, 32°C, 31°C, 30°C, 33°C, 34°C, 32°C]; k_contact = 0.5 cm² / °C (contact area adjustment coefficient); Collect the temperature data monitored by the sensor: The temperature data includes the real-time temperature values of each monitoring point: [32°C, 31°C, 33°C, 34°C, 32°C, 31°C, 30°C, 33°C, 34°C, 32°C, 31°C, 30°C, 33°C, 34°C, 32°C]; Calculate the average temperature of the contact surface between the phase change material and the battery based on the temperature data: Average temperature = (32 + 31 + 33 + 34 + 32 + 31 + 30 + 33 + 34 + 32 + 31 + 30 + 33 + 34 + 32) / 15; Average temperature = 486 / 15 = 32.4°C; Compare the average temperature with the set target temperature range: The target temperature range is 30°C to 35°C; The current average temperature is 32.4°C, which is within the target temperature range.

[0054] Change the contact area by moving or adjusting the position and layout of the phase change material: If the average temperature is higher than the upper limit of the target temperature (e.g., 35°C), increase the contact area between the PCM and the battery.

[0055] If the average temperature is lower than the lower limit of the target temperature (e.g., 30°C), reduce the contact area between the PCM and the battery.

[0056] In this example, the average temperature is 32.4°C, which is within the target temperature range, so there is no need to adjust the contact area.

[0057] Hypothetical scenario: Assume that in a certain measurement, the average temperature is 36°C (exceeding the upper limit of the target temperature of 35°C); Change in contact area = k_contact × (average temperature - target temperature); Change in contact area = 0.5 cm² / °C × (36°C - 35°C) = 0.5 cm²; Therefore, it is necessary to increase the contact area between the PCM and the battery by 0.5 cm² to reduce the average temperature.

[0058] Through the above steps, this method can dynamically adjust the contact area between the PCM and the battery based on sensor data, thereby precisely controlling the operating temperature of the battery pack. First, collect the real-time temperature values at each monitoring point, and then calculate the average temperature of the contact surface between the PCM and the battery. Next, compare the average temperature with the set target temperature range to determine whether the contact area needs to be adjusted. Finally, change the contact area by moving or adjusting the position and layout of the PCM to ensure that the PCM can absorb or release heat in the optimal state and maintain the operating temperature of the battery pack within the target range.

[0059] V. Controlling the heat absorption rate by changing the contact area; including the following steps: Measure the current contact area between the phase change material and the battery; Contact area = projected area of the phase change material on the battery surface; By measuring the projected area of the phase change material (PCM) on the battery surface, the contact situation between the PCM and the battery can be accurately understood.

[0060] Calculate the current heat absorption rate based on the contact area and real-time temperature data; Heat absorption rate = (T_environment - T_phase change material) × contact area / R_thermal, where T_environment is the ambient temperature, T_phase change material is the average temperature of the phase change material, and R_thermal is the thermal resistance between the phase change material and the battery; By calculating the heat absorption rate, the current heat absorption capacity of the PCM can be evaluated, and based on this, it can be determined whether the contact area between the PCM and the battery needs to be adjusted to optimize heat management.

[0061] Compare the heat absorption rate with the set target absorption rate; If the heat absorption rate is lower than the target absorption rate, increase the contact area between the phase change material and the battery; If the heat absorption rate is higher than the target absorption rate, decrease the contact area between the phase change material and the battery; Adjust the position or layout of the phase change material to change the contact area; New contact area = current contact area + ΔA_contact, where ΔA_contact = k_abs_rate × (target absorption rate - current heat absorption rate), and k_abs_rate is the absorption rate adjustment coefficient. By adjusting the position or layout of the PCM to change its contact area with the battery, the heat absorption rate can be effectively controlled to ensure that the PCM can absorb heat in the optimal state and maintain the operating temperature of the battery pack within the target range.

[0062] Suppose a new energy vehicle battery pack and its phase change material (PCM) are as follows: Initial contact area: 100 cm²; Ambient temperature (T_environment): 25 °C; Average temperature of the phase change material (T_phase change material): 30 °C; Thermal resistance (R_thermal) between the phase change material and the battery: 0.05 K / W; Set target absorption rate: 100 W; Absorption rate adjustment coefficient (k_abs_rate): 0.5 cm² / W; Measure the current contact area between the phase change material and the battery: Contact area = 100 cm²; Calculate the current heat absorption rate based on the contact area and real-time temperature data: Heat absorption rate = (T_environment - T_phase_change_material) × contact area / R_thermal; Heat absorption rate = (25°C - 30°C) × 100 cm² / 0.05 K / W; Heat absorption rate = (-5°C) × 100 cm² / 0.05 K / W = -1000 W; Compare the heat absorption rate with the set target absorption rate: The current heat absorption rate is -1000 W, while the set target absorption rate is 100 W.

[0063] Therefore, the current heat absorption rate is lower than the target absorption rate.

[0064] Adjust the position or layout of the phase change material to change the contact area: New contact area = current contact area + ΔA_contact; ΔA_contact = k_abs_rate × (target absorption rate - current heat absorption rate); ΔA_contact = 0.5 cm² / W × (100 W - (-1000 W)) = 0.5 cm² / W × 1100 W = 550 cm²; New contact area = 100 cm² + 550 cm² = 650 cm²; Through the above steps, this method can dynamically adjust the contact area between the PCM and the battery, thereby precisely controlling the heat absorption rate. First, measure the contact area between the PCM and the battery, and then calculate the current heat absorption rate based on the contact area and real-time temperature data. Then, compare the heat absorption rate with the set target absorption rate to determine whether the contact area needs to be adjusted. Finally, change the contact area by adjusting the position or layout of the PCM to ensure that the PCM can absorb heat in the best state and maintain the operating temperature of the battery pack within the target range. This method improves the temperature control accuracy of the battery pack, optimizes the overall performance of the system, and enhances the safety and reliability of the vehicle.

[0065] In the above embodiments, since the current heat absorption rate is lower than the target absorption rate, the system increases the contact area between the PCM and the battery to improve the heat absorption efficiency, and finally makes the new contact area reach 650 cm² to better meet the heat absorption requirements.

[0066] VI. Adjust the internal structure layout of the phase change material using the heat absorption rate; including the following steps: Determine the working state of the current phase change material according to the heat absorption rate; if the heat absorption rate is high, it indicates that the phase change material is in a rapid heat absorption state; if the heat absorption rate is low, it indicates that the phase change material is in a slow heat absorption or stable state; Adjust the heat conduction path inside the phase change material based on the heat absorption rate; the heat conduction path adjustment amount = k_path × (target absorption rate - current heat absorption rate), where k_path is the heat conduction path adjustment coefficient; by adjusting the heat conduction path inside the PCM, the heat conduction efficiency can be optimized. Increasing the heat conduction path can improve the heat conduction efficiency, and reducing the heat conduction path can reduce the heat conduction efficiency to ensure that the PCM can work effectively under different working conditions.

[0067] Increase the heat conduction path to improve the heat conduction efficiency, reduce the heat conduction path to reduce the heat conduction efficiency; redistribute the reinforcing material inside the phase change material to optimize the heat conduction path; the distribution density of the reinforcing material = D_0 + ΔD_mat, where D_0 is the initial distribution density, ΔD_mat = k_dens × (heat conduction path adjustment amount), and k_dens is the distribution density adjustment coefficient; when the distribution density increases, the reinforcing material is more concentrated in the high-temperature area, and vice versa in the low-temperature area; by redistributing the reinforcing material, the heat conduction path can be increased in the high-temperature area to improve the heat conduction efficiency; the heat conduction path can be reduced in the low-temperature area to avoid unnecessary heat loss, thereby achieving a uniform temperature distribution inside the PCM.

[0068] Adjust the overall layout of the phase change material according to the new distribution of the reinforcing material; the phase change material layout change amount = L_0 + ΔL_mod, where L_0 is the initial layout parameter, ΔL_mod = k_layout × (change in the distribution density of the reinforcing material), and k_layout is the layout adjustment coefficient; the adjusted layout ensures that the phase change material can absorb and release heat more evenly, keeping the temperature of the battery pack stable.

[0069] Suppose a new energy vehicle battery pack and its phase change material (PCM) are as follows: Initial heat absorption rate: 80 W; Target absorption rate: 100 W; Initial heat conduction path length: L_0 = 5 cm; Initial distribution density of the reinforcing material: D_0 = 2 g / cm³; Initial layout parameter: L_0 = 10 cm; Thermal conduction path adjustment coefficient: k_path = 0.1 cm / W; Distribution density adjustment coefficient: k_dens = 0.05 g / cm³ / W; Layout adjustment coefficient: k_layout = 0.2 cm / g / cm³; Determine the working state of the current phase change material according to the heat absorption rate: The current heat absorption rate is 80 W, which is lower than the target absorption rate of 100 W, indicating that the PCM is in a slow heat absorption state.

[0070] Adjust the thermal conduction path inside the phase change material based on the heat absorption rate: Thermal conduction path adjustment amount = k_path × (target absorption rate - current heat absorption rate); Thermal conduction path adjustment amount = 0.1 cm / W × (100 W - 80 W) = 0.1 cm / W × 20 W = 2 cm; New thermal conduction path length = initial thermal conduction path length + thermal conduction path adjustment amount = 5 cm + 2 cm = 7 cm; Redistribute the reinforcing material inside the phase change material to optimize the thermal conduction path: Reinforcing material distribution density = D_0 + ΔD_mat; ΔD_mat = k_dens × (thermal conduction path adjustment amount) = 0.05 g / cm³ / W × 20 W = 1 g / cm³; Reinforcing material distribution density = 2 g / cm³ + 1 g / cm³ = 3 g / cm³; Adjust the overall layout of the phase change material according to the new distribution of the reinforcing material: Phase change material layout change amount = L_0 + ΔL_mod; ΔL_mod = k_layout × (change in reinforcing material distribution density) = 0.2 cm / g / cm³ × 1 g / cm³ = 0.2 cm; New phase change material layout = initial layout parameter + layout change amount = 10 cm + 0.2 cm = 10.2 cm; Through the above steps, this method can dynamically adjust the internal structural layout of the PCM using the heat absorption rate to ensure that the PCM can absorb and release heat in the optimal state. First, determine the current working state of the PCM according to the heat absorption rate, and then adjust the heat conduction path inside the PCM according to the heat absorption rate. Next, redistribute the reinforcing material to optimize the heat conduction path, and adjust the overall layout of the PCM according to the new distribution of the reinforcing material. Finally, this method improves the heat management efficiency of the PCM, ensures that the battery pack can maintain a stable temperature under various working conditions, extends the battery life, and improves the overall performance of the system.

[0071] In the above embodiment, since the current heat absorption rate is lower than the target absorption rate, the system improves the heat conduction efficiency by increasing the heat conduction path length and the distribution density of the reinforcing material of the PCM. Finally, the new heat conduction path length reaches 7 cm, the distribution density of the reinforcing material reaches 3 g / cm³, and the overall layout of the PCM is adjusted to 10.2 cm to better meet the heat absorption requirements.

[0072] VII. Optimize the heat release rate of the phase change material according to the structural layout; including the following steps: Measure the current temperature distribution inside the phase change material; the temperature distribution = (T_1, T_2,..., T_n), where T_1 to T_n are the temperature values of each monitoring point; by measuring the temperature values of each monitoring point inside the PCM, the temperature distribution inside the PCM can be comprehensively understood. This provides the basic data for subsequent calculation of the heat release rate and adjustment of the internal structure of the PCM.

[0073] Calculate the current heat release rate of the phase change material based on the temperature distribution and the structural layout; the heat release rate = (T_phase change material - T_environment) × contact area / R_thermal, where T_phase change material is the average temperature of the phase change material, T_environment is the ambient temperature, the contact area is the contact area between the phase change material and the battery, and R_thermal is the thermal resistance between the phase change material and the battery; by calculating the heat release rate, the current heat dissipation capacity of the PCM can be evaluated, and based on this, it can be judged whether it is necessary to adjust the internal structure of the PCM to optimize the heat management.

[0074] Compare the heat release rate with the set target release rate; if the heat release rate is lower than the target release rate, then adjust the distribution density of the reinforcing material inside the phase change material; the new distribution density = current distribution density + ΔD_release, where ΔD_release = k_rel_rate × (target release rate - current heat release rate), and k_rel_rate is the release rate adjustment coefficient; Rearrange the heat conduction paths within the phase change material according to the new distribution density; the amount of heat conduction path adjustment = L_0 + ΔL_release, where L_0 is the initial heat conduction path length, ΔL_release = k_path_rel × (new distribution density - current distribution density), and k_path_rel is the heat conduction path adjustment coefficient; the adjusted heat conduction paths ensure that heat can be transferred from the phase change material to the battery or the environment more evenly, thereby maintaining the stable operating temperature of the battery pack.

[0075] Suppose a battery pack of a new energy vehicle and its phase change material (PCM) are as follows: Number of monitoring points: 15; Initial temperature distribution: [34°C, 33°C, 35°C, 36°C, 34°C, 33°C, 32°C, 35°C, 36°C, 34°C, 33°C, 32°C, 35°C, 36°C, 34°C]; Ambient temperature (T_environment): 25°C; Contact area: 100 cm²; Thermal resistance (R_thermal): 0.05 K / W; Set target release rate: 80 W; Release rate adjustment coefficient (k_rel_rate): 0.1 g / cm³ / W; Initial distribution density (D_0): 2 g / cm³; Initial heat conduction path length (L_0): 5 cm; Heat conduction path adjustment coefficient (k_path_rel): 0.2 cm / g / cm³; Measure the current temperature distribution inside the phase change material: Temperature distribution = [34°C, 33°C, 35°C, 36°C, 34°C, 33°C, 32°C, 35°C, 36°C, 34°C, 33°C, 32°C, 35°C, 36°C, 34°C]; Calculate the current heat release rate of the phase change material based on the temperature distribution and structural layout: Average temperature (T_phase change material) = (34 + 33 + 35 + 36 + 34 + 33 + 32 + 35 + 36 + 34 + 33 + 32 + 35 + 36 + 34) / 15 = 34°C; Heat release rate = (T_phase change material - T_environment) × contact area / R_thermal; Heat release rate = (34°C - 25°C) × 100 cm² / 0.05 K / W = 9°C × 100 cm² / 0.05 K / W = 1800 W; Compare the heat release rate with the set target release rate: The current heat release rate is 1800 W, while the set target release rate is 80 W.

[0076] Therefore, the current heat release rate is much higher than the target release rate.

[0077] Rearrange the heat conduction paths within the phase change material according to the new distribution density: New distribution density = Current distribution density + ΔD_release; ΔD_release = k_rel_rate × (Target release rate - Current heat release rate): ΔD_release = 0.1 g / cm³ / W × (80 W - 1800 W) = 0.1 g / cm³ / W × (-1720 W) = -172 g / cm³; New distribution density = 2 g / cm³ + (-172 g / cm³) = -170 g / cm³ (obviously unreasonable and needs to be corrected); Correction method: If the calculation result is unreasonable (such as a negative value), it can be corrected by restricting the adjustment range. For example, set the minimum distribution density to 1 g / cm³.

[0078] New distribution density = max(1 g / cm³, Current distribution density + ΔD_release); New distribution density = max(1 g / cm³, 2 g / cm³ - 172 g / cm³) = 1 g / cm³; Heat conduction path adjustment amount = L_0 + ΔL_release; ΔL_release = k_path_rel × (New distribution density - Current distribution density); ΔL_release = 0.2 cm / g / cm³ × (1 g / cm³ - 2 g / cm³) = 0.2 cm / g / cm³ × (-1 g / cm³) = -0.2 cm; New heat conduction path length = L_0 + ΔL_release = 5 cm - 0.2 cm = 4.8 cm; Through the above steps, this method can dynamically adjust the internal structure layout of the PCM using the heat release rate to ensure that the PCM can release heat in the optimal state. First, measure the temperature values at each monitoring point inside the PCM, and then calculate the current heat release rate based on the temperature distribution and structure layout. Next, compare the heat release rate with the set target release rate to determine whether it is necessary to adjust the distribution density of the reinforcing material inside the PCM. Finally, rearrange the heat conduction paths inside the PCM according to the new distribution density to ensure that heat can be transferred from the PCM to the battery or the environment more evenly, thereby maintaining the stable operating temperature of the battery pack.

[0079] In the above embodiment, since the current heat release rate is much higher than the target release rate, the system reduces the distribution density of the reinforcing material inside the PCM and shortens the length of the heat conduction path to reduce the heat release rate. Finally, the new distribution density reaches 1 g / cm³ and the heat conduction path length reaches 4.8 cm to better meet the heat release requirements.

[0080] VIII. Maintaining the stable operating temperature of the battery pack based on the heat release rate; including the following steps: Monitor the heat release rate of the current phase change material; the heat release rate = (T_phase change material - T_environment) × contact area / R_thermal, where T_phase change material is the average temperature of the phase change material, T_environment is the ambient temperature, the contact area is the contact area between the phase change material and the battery, and R_thermal is the thermal resistance between the phase change material and the battery; by monitoring the heat release rate of the PCM in real time, the current heat dissipation capacity of the PCM can be understood.

[0081] Calculate the actual temperature change of the battery pack based on the heat release rate; the actual temperature change = ΔT_battery = (heat release rate × time period) / (battery pack mass × specific heat capacity), where the time period is the monitoring time interval, the battery pack mass is the mass of the battery pack, and the specific heat capacity is the specific heat capacity of the battery material; by calculating the actual temperature change, the impact of the PCM on the temperature of the battery pack can be evaluated, and based on this, it can be determined whether it is necessary to adjust the heat release rate of the PCM to maintain the stable operating temperature of the battery pack.

[0082] Compare the actual temperature change with the set target temperature range; if ΔT_battery exceeds the upper limit of the target temperature range, reduce the heat release rate of the phase change material; if ΔT_battery is lower than the lower limit of the target temperature range, increase the heat release rate of the phase change material; Adjust the heat release rate by adjusting the distribution of the reinforcing material inside the phase change material and the heat conduction path; the new distribution density = the current distribution density + ΔD_control, where ΔD_control = k_temp_ctrl × (the median of the target temperature range - the actual temperature change), and k_temp_ctrl is the temperature control adjustment coefficient; the heat conduction path adjustment amount = L_0 + ΔL_control, where L_0 is the initial heat conduction path length, ΔL_control = k_path_ctrl × (the new distribution density - the current distribution density), and k_path_ctrl is the heat conduction path adjustment coefficient; the adjusted layout ensures that the phase change material can more effectively control the heat release rate and keep the operating temperature of the battery pack within the target range.

[0083] Suppose a battery pack of a new energy vehicle and its phase change material (PCM) are as follows: Number of monitoring points: 15; Initial temperature distribution: [34°C, 33°C, 35°C, 36°C, 34°C, 33°C, 32°C, 35°C, 36°C, 34°C, 33°C, 32°C, 35°C, 36°C, 34°C]; Ambient temperature (T_environment): 25°C; Contact area: 100 cm²; Thermal resistance (R_thermal): 0.05 K / W; Set target temperature range: 30°C to 35°C; Time period: 1 hour; Battery pack mass: 50 kg; Specific heat capacity: 900 J / (kg·°C); Temperature control adjustment coefficient (k_temp_ctrl): 0.05 g / cm³ / °C; Initial distribution density (D_0): 2 g / cm³; Initial heat conduction path length (L_0): 5 cm; Heat conduction path adjustment coefficient (k_path_ctrl): 0.2 cm / g / cm³.

[0084] Monitor the heat release rate of the current phase change material: Average temperature (T_phase change material) = (34 + 33 + 35 + 36 + 34 + 33 + 32 + 35 + 36 + 34 + 33 + 32 + 35 + 36 + 34) / 15 = 34°C; Heat release rate = (T_phase change material - T_environment) × contact area / R_thermal; Heat release rate = (34°C - 25°C) × 100 cm² / 0.05 K / W = 9°C × 100 cm² / 0.05 K / W = 1800 W; Calculate the actual temperature change of the battery pack based on the heat release rate: Actual temperature change (ΔT_battery) = (Heat release rate × Time period) / (Battery pack mass × Specific heat capacity); Actual temperature change = (1800 W × 3600 s) / (50 kg × 900 J / (kg·°C)); Actual temperature change = 6480000 J / 45000 J / °C = 144°C; Compare the actual temperature change with the set target temperature range: The set target temperature range is from 30°C to 35°C; The current actual temperature change is 144°C, which is clearly much higher than the upper limit of the target temperature range.

[0085] Adjust the heat release rate by adjusting the internal reinforcement material distribution and heat conduction path in the phase change material: New distribution density = Current distribution density + ΔD_control; ΔD_control = k_temp_ctrl × (Median of the target temperature range - Actual temperature change); Median of the target temperature range = (30°C + 35°C) / 2 = 32.5°C; ΔD_control = 0.05 g / cm³ / °C × (32.5°C - 144°C) = 0.05 g / cm³ / °C × (-111.5°C) = -5.575 g / cm³; New distribution density = 2 g / cm³ + (-5.575 g / cm³) = -3.575 g / cm³ (unreasonable, correct); Correction method: Set the minimum distribution density to 1 g / cm³.

[0086] New distribution density = max(1 g / cm³, Current distribution density + ΔD_control); New distribution density = max(1 g / cm³, 2 g / cm³ - 5.575 g / cm³) = 1 g / cm³; Adjustment amount of the heat conduction path = L_0 + ΔL_control; ΔL_control = k_path_ctrl × (New distribution density - Current distribution density); ΔL_control = 0.2 cm / g / cm³ × (1 g / cm³ - 2 g / cm³) = 0.2 cm / g / cm³ × (-1 g / cm³) = -0.2 cm; The new thermal conduction path length = L_0 + ΔL_control = 5 cm - 0.2 cm = 4.8 cm; Through the above steps, this method can dynamically adjust the internal structure layout of the PCM using the heat release rate, ensuring that the PCM can release heat in the optimal state and maintain the operating temperature of the battery pack within the target range. First, monitor the heat release rate of the PCM, and then calculate the actual temperature change of the battery pack based on the heat release rate. Next, compare the actual temperature change with the set target temperature range to determine whether it is necessary to adjust the heat release rate of the PCM. Finally, by adjusting the distribution density of the internal reinforcing material and the thermal conduction path in the PCM, ensure that the PCM can more effectively control the heat release rate and keep the operating temperature of the battery pack within the target range.

[0087] In the above embodiment, since the current actual temperature change is much higher than the target temperature range, the system reduces the distribution density of the internal reinforcing material in the PCM and shortens the thermal conduction path length to reduce the heat release rate. Finally, the new distribution density reaches 1 g / cm³ and the thermal conduction path length reaches 4.8 cm to better meet the heat release requirements and maintain the stable operating temperature of the battery pack.

[0088] On the other hand, the present invention also proposes a thermal management module system applicable to new energy vehicle batteries, as Figure 2 shown, including: An operating temperature determination module for determining the operating temperature range of the battery pack; A phase change material selection module for selecting a phase change material according to the operating temperature range; A sensor arrangement and monitoring module for arranging sensors in the phase change material to monitor temperature changes; A contact area adjustment module for adjusting the contact area between the phase change material and the battery based on the sensor data; A heat absorption rate control module for controlling the heat absorption rate by changing the contact area; An internal structure layout adjustment module for adjusting the internal structure layout of the phase change material using the heat absorption rate; A heat release rate optimization module for optimizing the heat release rate of the phase change material according to the structure layout; A battery pack temperature stability maintenance module for maintaining the stable operating temperature of the battery pack based on the heat release rate.

[0089] Further, when the above modules are executed, they are also used to implement other steps of the above-mentioned thermal management control method for a new energy vehicle battery, which will not be elaborated here one by one.

[0090] In summary, the present invention determines the operating temperature range of the battery pack, selects a suitable phase change material, arranges sensors in the phase change material to monitor temperature changes, adjusts the contact area between the phase change material and the battery based on sensor data, controls the heat absorption rate by changing the contact area, regulates the internal structure layout of the phase change material using the heat absorption rate, optimizes the heat release rate of the phase change material according to the structure layout, and finally maintains the stable operating temperature of the battery pack based on the heat release rate.

[0091] This method can accurately control the heat absorption and release rates, effectively avoid the influence of local temperature fluctuations on the battery life and performance, significantly improve the stability and reliability of the battery pack during rapid charge and discharge cycles, while enhancing the safety and service life of the system, and reducing complexity and maintenance costs.

[0092] Finally, it should be noted that the above are only the preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments, or perform equivalent replacements for some of the technical features. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A thermal management control method for a new energy vehicle battery, characterized in that, It includes the following steps: Determine the operating temperature range of the battery pack, measure the initial temperature values of the battery pack under different working conditions, select phase change materials according to the operating temperature range, conduct thermal conductivity tests on the phase change materials, and calculate the thermal conductivity coefficients of each material; Arrange sensors in the phase change materials to monitor temperature changes, collect the temperature data monitored by the sensors, and adjust the contact area between the phase change materials and the battery based on the temperature data of the sensors; Control the heat absorption rate by changing the contact area, calculate the current heat absorption rate according to the contact area and real-time temperature data, and adjust the internal structure layout of the phase change materials using the heat absorption rate; Optimize the heat release rate of the phase change materials according to the structure layout, and maintain the stable operating temperature of the battery pack based on the heat release rate.

2. The thermal management control method of a new energy vehicle battery according to claim 1, characterized in that, The step of determining the operating temperature range of the battery pack and measuring the initial temperature values of the battery pack under different working conditions includes the following steps: Based on the initial temperature value, calculate the highest and lowest operating temperature limits; where the highest operating temperature limit is the initial temperature value plus the maximum temperature difference, and the lowest operating temperature limit is the initial temperature value minus the minimum temperature difference; According to the highest and lowest operating temperature limits, divide into multiple temperature intervals, and the width of each temperature interval is determined by the highest and lowest operating temperature limits; For each temperature interval, set the corresponding phase change trigger conditions of the phase change materials. When the detected battery temperature reaches the upper or lower limit of the temperature interval, start the phase change process of the corresponding phase change material to adjust the battery temperature back into the target interval.

3. A thermal management control method for a new energy vehicle battery according to claim 2, characterized in that, The step of selecting phase change materials according to the operating temperature range, conducting thermal conductivity tests on the phase change materials, and calculating the thermal conductivity coefficients of each material includes the following steps: Determine the average temperature value within the operating temperature range, and the average temperature value is the average of the highest operating temperature limit and the lowest operating temperature limit; Based on the average temperature value, screen out the candidate phase change materials that meet this temperature range, and the screening condition is that the phase change temperature of the candidate phase change materials is within the range of the average temperature value; Conduct thermal conductivity tests on the candidate phase change materials and calculate the thermal conductivity coefficients of each material; According to the thermal conductivity coefficients, select the phase change material with the highest thermal conductivity as the final choice. When multiple candidate phase change materials have the same highest thermal conductivity coefficient, select the material with the smallest density to optimize the overall weight of the battery pack.

4. A thermal management control method for a new energy vehicle battery according to claim 3, characterized in that, The step of arranging sensors in the phase change materials to monitor temperature changes includes the following steps: Determine the geometric shape and size of the phase change materials; Based on the geometric shape and size, evenly distribute multiple monitoring points inside the phase change materials, and the number of monitoring points is determined according to the volume of the phase change materials and the volume covered by a single monitoring point; Install temperature sensors at each monitoring point and record the initial temperature value. The spacing between the temperature sensors is determined according to the length of the longest side of the phase change materials and the number of monitoring points; Transmit the temperature data to the central control system through the data lines connecting all the temperature sensors.

5. A thermal management control method for a new energy vehicle battery according to claim 4, characterized in that The step of collecting the temperature data monitored by the sensors and adjusting the contact area between the phase change materials and the battery based on the temperature of the sensors includes the following steps: Collect the temperature data monitored by the sensor, where the temperature data includes the real-time temperature values of each monitoring point; Calculate the average temperature of the contact surface between the phase change material and the battery based on the temperature data, and the average temperature is the average of the temperature values of each monitoring point; Compare the average temperature with the set target temperature range; if the average temperature is higher than the upper limit of the target temperature, increase the contact area between the phase change material and the battery; if the average temperature is lower than the lower limit of the target temperature, reduce the contact area between the phase change material and the battery; Change the contact area by moving or adjusting the position and layout of the phase change material.

6. A thermal management control method for a new energy vehicle battery according to claim 5, characterized in that, The heat absorption rate is controlled by changing the contact area, and the current heat absorption rate is calculated based on the contact area and the real-time temperature data, including the following steps: Measure the current contact area between the phase change material and the battery, and the contact area is the projected area of the phase change material on the battery surface; Compare the heat absorption rate with the set target absorption rate; if the heat absorption rate is lower than the target absorption rate, increase the contact area between the phase change material and the battery; if the heat absorption rate is higher than the target absorption rate, reduce the contact area between the phase change material and the battery; Adjust the position or layout of the phase change material to change the contact area.

7. A thermal management control method for a new energy vehicle battery according to claim 6, characterized in that The internal structure layout of the phase change material is adjusted using the heat absorption rate, including the following steps: Determine the current working state of the phase change material based on the heat absorption rate; if the heat absorption rate is high, it indicates that the phase change material is in a rapid heat absorption state; if the heat absorption rate is low, it indicates that the phase change material is in a slow heat absorption or stable state; Adjust the heat conduction path inside the phase change material based on the heat absorption rate; Redistribute the reinforcing material inside the phase change material to optimize the heat conduction path. When the distribution density increases, the reinforcing material is more concentrated in the high-temperature area, and vice versa, it is concentrated in the low-temperature area; Adjust the overall layout of the phase change material according to the new distribution of the reinforcing material.

8. A thermal management control method for a new energy vehicle battery according to claim 7, characterized in that, The heat release rate of the phase change material is optimized according to the structure layout, including the following steps: Measure the current temperature distribution inside the phase change material, and the temperature distribution is the temperature values of each monitoring point; Calculate the current heat release rate of the phase change material based on the temperature distribution and the structure layout; Compare the heat release rate with the set target release rate; if the heat release rate is lower than the target release rate, adjust the distribution density of the reinforcing material inside the phase change material; if the heat release rate is higher than the target release rate, reduce the distribution density of the reinforcing material inside the phase change material; Rearrange the heat conduction path inside the phase change material according to the new distribution density.

9. A thermal management control method for a new energy vehicle battery according to claim 8, characterized in that, Maintain the stable operating temperature of the battery pack based on the heat release rate, including the following steps: Monitor the heat release rate of the current phase change material; Calculate the actual temperature change of the battery pack based on the heat release rate; Compare the actual temperature change with the set target temperature range; if the actual temperature change exceeds the upper limit of the target temperature range, reduce the heat release rate of the phase change material; if the actual temperature change is lower than the lower limit of the target temperature range, increase the heat release rate of the phase change material; Adjust the heat release rate by adjusting the distribution of the reinforcing material and the heat conduction path inside the phase change material, so that the operating temperature of the battery pack is maintained within the target range.

10. A thermal management module system for a new energy vehicle battery, which is applicable to implement the thermal management control method according to any one of claims 1-9, characterized in that, Including: An operating temperature determination module for determining the operating temperature range of the battery pack; A phase change material selection module for selecting a phase change material according to the operating temperature range; A sensor arrangement and monitoring module for arranging sensors in the phase change material to monitor temperature changes; A contact area adjustment module for adjusting the contact area between the phase change material and the battery based on the sensor data; A heat absorption rate control module for controlling the heat absorption rate by changing the contact area; An internal structure layout adjustment module for adjusting the internal structure layout of the phase change material by using the heat absorption rate; A heat release rate optimization module for optimizing the heat release rate of the phase change material according to the structure layout; A battery pack temperature stability maintenance module for maintaining the stable operating temperature of the battery pack according to the heat release rate.

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