Liquid cooling plate with variable flow channel structure and application method thereof

Abstract

The application discloses a liquid cooling plate with variable flow channel structure, comprising a first surface layer, a second surface layer and a flow channel layer sandwiched between the first surface layer and the second surface layer; variable flow channel components arranged in a continuous grid are arranged on the first surface layer, each variable flow channel component is in close contact with an adjacent variable flow channel component; the variable flow channel components are configured to be independently deformed, and a plurality of variable flow channel components are combined to form a flow channel layer after deformation, so that the flow channel layer is adapted to a certain heat exchange working condition. The application further discloses an application method of the liquid cooling plate with variable flow channel structure, and the application method is applied to a power battery. The application can achieve optimal battery thermal management effect under different working conditions, and effectively improves the performance safety of the battery system under various working conditions.

Description

Technical Field

[0001] This invention relates to a liquid cooling plate and its application method, belonging to the field of battery cooling technology. Background Technology

[0002] Liquid cooling plates for power battery packs and energy storage systems in new energy vehicles are crucial for battery thermal management. Topology optimization, a key method in liquid cooling plate flow channel design, effectively reduces local flow stagnation and dead zones by optimizing the coolant flow path, resulting in more uniform fluid distribution and thus improving overall heat exchange efficiency.

[0003] However, the flow rate of the cooling medium varies under different operating conditions, which necessitates corresponding changes to the structure of the topology-optimized flow channel. In practice, the topology-optimized flow channel for the most commonly used operating conditions is usually selected as the final flow channel solution. While this approach satisfies the needs of common operating conditions to some extent, it ignores the specificities of other operating conditions. The final selected flow channel often fails to achieve ideal cooling performance under other operating conditions, making it difficult to meet the diverse thermal management requirements of the battery under different conditions.

[0004] Patent CN221575907U discloses a variable flow channel liquid-cooled plate structure. The liquid-cooled plate has multiple partitions inside, forming multiple flow channels. Multiple openings are provided on the partitions, each containing a slider, a spring, an armature, and a coil. The slider is connected above the spring, the coil is positioned below the spring, and the armature is located outside the spring. When the coil is not energized, the spring pushes the slider upwards; when the coil is energized, it generates electromagnetic force, causing the armature to move the slider downwards. After the slider moves upwards or downwards, the openings of the partitions close or open accordingly, connecting the flow channels with adjacent channels at the open openings, thus changing the flow channel configuration.

[0005] The variable flow channel of the above technical solution can vary in shape at local locations, but due to the flow channel formed by the baffle, the shape of most of the flow channel remains fixed, which makes it difficult to fully match the heat exchange needs of the heating element in various different working states. Summary of the Invention

[0006] To address the shortcomings of the prior art, the present invention aims to provide a liquid cooling plate with a variable flow channel structure, solving the problem that fixed-shape liquid cooling plates or liquid cooling plates with simple, regular deformations cannot fully match the heat exchange requirements of the heat-generating element under various operating conditions. Another objective of the present invention is to provide a method for applying the liquid cooling plate with a variable flow channel structure.

[0007] The technical solution of the present invention is as follows: a liquid cooling plate with a variable flow channel structure, comprising a first surface layer, a second surface layer, and a flow channel layer sandwiched between the first surface layer and the second surface layer;

[0008] The first surface layer is provided with variable flow channel components arranged in a continuous grid, and each variable flow channel component is in close contact with the adjacent variable flow channel component;

[0009] The variable flow channel components are configured such that each component can deform independently, and several variable flow channel components are combined after deformation to form a flow channel layer that adapts to a certain heat exchange condition.

[0010] Furthermore, the continuous grid is arranged in a rectangular grid array.

[0011] Furthermore, the side length of a single variable flow channel component is less than one-fiftieth of the shortest side length of the liquid cooling plate.

[0012] Furthermore, the variable flow channel component adopts telescopic columns, and the telescopic direction of the telescopic columns is perpendicular to the first surface layer; when the liquid cooling plate is in the initial state, all telescopic columns retract into the first surface layer.

[0013] Furthermore, when the telescopic column retracts into the first surface layer, the top surface of the telescopic column does not extend beyond the inner surface of the first surface layer.

[0014] Furthermore, when the telescopic column extends into the second surface layer, the top surface of the telescopic column contacts the inner surface of the second surface layer.

[0015] Furthermore, the extension and retraction of the telescopic column is controlled by a motor, electromagnetic force, or hydraulic pressure.

[0016] Another technical solution of the present invention is: a method for applying a liquid cooling plate with a variable flow channel structure, wherein the aforementioned liquid cooling plate with a variable flow channel structure is applied to a power battery, comprising the following steps:

[0017] Step 1: Based on the topology optimization algorithm, obtain the cooling flow channel diagrams of the first and second operating states of the power battery, which are the first cooling flow channel diagram and the second cooling flow channel diagram, respectively.

[0018] Step 2: Compare the first cooling channel diagram with the liquid cooling plate in the initial state to obtain the telescopic column that the liquid cooling plate with variable channel structure needs to extend for the first time, which is denoted as the first deformation group.

[0019] Step 3: Compare the second cooling channel diagram with the liquid cooling plate in the initial state to obtain the telescopic column that the liquid cooling plate with variable channel structure needs to extend for the second time, which is denoted as the second deformation group;

[0020] Step 4: The variable flow channel structure liquid cooling plate is installed on the power battery and configured such that: when the power battery is in the first working state, all the telescopic columns of the first deformation group extend and the remaining telescopic columns retract, in order to fit the first cooling flow channel diagram; when the power battery is in the second working state, all the telescopic columns of the second deformation group extend and the remaining telescopic columns retract, in order to fit the second cooling flow channel diagram.

[0021] Furthermore, step 2 includes the following sub-steps:

[0022] Step 2.1: Mesh the first cooling channel diagram according to the continuous mesh pattern of the liquid cooling plate with variable flow channel structure;

[0023] Step 2.2: Measure and calculate the projected area of ​​the flow channel region in the first cooling flow channel diagram that falls into the corresponding grid;

[0024] Step 2.3: When the projected area of ​​the flow channel within the grid is less than half of the total area of ​​the grid, the telescoping column of the grid belongs to the first deformation group.

[0025] Furthermore, step 2 also includes the following steps:

[0026] Step 2.4: When the projected area of ​​the flow channel in the grid is zero, and the projected area of ​​each flow channel in the eight grids directly adjacent to the grid is less than half the area of ​​a single grid, the telescopic column of the grid does not belong to the first deformation group.

[0027] Compared with the prior art, the advantages of the technical solution provided by the present invention are as follows:

[0028] By utilizing the deformation of variable flow channel components with continuous grid arrangement, the flow channels of the flow channel layer can be significantly changed to adapt to different flow channel topologies. It does not rely on multiple fixed flow channel forms to limit the matching degree between the flow channel and the heat dissipation of the heat source, thus achieving or approaching the optimal heat dissipation effect under different operating conditions. When applied to power batteries, it can improve the battery thermal management effect and effectively improve the performance and safety of the battery system under various operating conditions. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the structure of a liquid cooling plate with a variable flow channel.

[0030] Figure 2 This is a preferred embodiment of the present invention, showing the cooling flow channel diagram of the power battery in its first operating state obtained by topology optimization design.

[0031] Figure 3 Yes Figure 2 A schematic diagram of the liquid cooling plate flow channel diagram in a gridded form.

[0032] Figure 4 Yes Figure 3 A schematic diagram illustrating the recognition and processing of the area outlined by the dashed box.

[0033] Figure 5 yes Figure 3 A magnified view of a section, the area outlined by the dashed box is... Figure 3 same.

[0034] Figure 6 This is a schematic diagram in the topology diagram excluding the variable flow channel component from the first deformation group.

[0035] Figure 7 This is a schematic diagram of a hollow blocking section formed by a variable flow channel component. Detailed Implementation

[0036] The present invention will be further described below with reference to embodiments. It should be understood that these embodiments are only for illustrating the present invention and are not intended to limit the scope of the present invention. After reading this description, any modifications of this description in various equivalent forms by those skilled in the art will fall within the scope defined by the appended claims.

[0037] Please combine Figure 1 As shown, the liquid cooling plate provided in this embodiment mainly consists of a first surface layer 1, a second surface layer 2, and a flow channel layer sandwiched between them. The first surface layer 1 plays a crucial foundational role in the flow channel construction. Variable flow channel components 3 are arranged in a continuous grid on the first surface layer 1, with each variable flow channel component 3 in close contact with its adjacent counterparts, leaving almost no gaps between them. This close-contact, continuous grid arrangement lays the foundation for the subsequent formation of diverse flow channel structures. It should be noted that the figure only shows a portion of the liquid cooling plate; the flow channel layer has boundaries that prevent coolant leakage. Furthermore, for ease of structural illustration, the second surface layer 2 is shown as being away from the variable flow channel components 3 in the figure; the actual positional relationship between the second surface layer 2 and the variable flow channel components 3 will be explained later.

[0038] In practical applications, a rectangular grid array is preferred for continuous meshes. Rectangular grids can be evenly distributed on the first surface layer 1, exhibiting regularity and ease of computational control, facilitating the positioning and operation of each variable flow channel component 3. The side length of a single variable flow channel component 3 must be less than one-fiftieth of the shortest side length of the liquid cooling plate, meaning that each side of the liquid cooling plate must have at least fifty variable flow channel components 3. This size design ensures both the flexibility of the variable flow channel components 3 and a sufficient number of components can be arranged within the limited area of ​​the liquid cooling plate to achieve diverse flow channel combinations and detailed simulation of flow channel shapes, better matching the cooling channel diagram obtained based on the topology optimization algorithm.

[0039] The variable flow channel component 3 employs telescopic columns, whose extension and retraction direction is perpendicular to the first surface layer 1. By extending and retracting different telescopic columns, flow channels of different shapes are constructed between the first surface layer 1 and the second surface layer 2. When the liquid cooling plate is in its initial state, all telescopic columns retract into the first surface layer 1. For example, in the initial state, to ensure smooth flow within the liquid cooling plate and avoid interfering with coolant flow, when the telescopic columns retract into the first surface layer 1, the top surface of the variable flow channel component 3 does not extend beyond the inner surface of the first surface layer 1. At this time, the telescopic columns are completely contained within the first surface layer 1, keeping the inner surface of the first surface layer 1 flat. When the telescopic columns extend into the second surface layer 2, the top surface of the variable flow channel component 3 contacts the inner surface of the second surface layer 2, and each flow channel is not connected to the top of adjacent flow channels, thus not affecting the vertical operation of the liquid cooling plate.

[0040] The extension and retraction of telescopic columns rely on motor, electromagnetic, or hydraulic control. Taking motor control as an example, a miniature motor can be connected to the bottom of each telescopic column via a lead screw. The extension and retraction of the column are controlled by the forward and reverse rotation of the motor. Motor control has the advantages of high precision and fast response speed, and can accurately adjust the state of the telescopic column according to preset requirements. If electromagnetic control is used, electromagnetic force can be used to drive the telescopic column. By controlling the magnitude and direction of the current, the electromagnetic force can be changed, thereby achieving precise control of the extension and retraction of the column. Hydraulic control uses the pressure generated by the hydraulic system to push the telescopic column. Hydraulic control is characterized by high output force and is suitable for situations requiring high driving force for the telescopic column.

[0041] The heat generation of power batteries varies significantly under different operating conditions. If the liquid cooling plate used to cool them has only one type of flow channel structure, it will be difficult to match different operating conditions. Traditional liquid cooling plates use a series of regularly arranged grooves for their flow channels. More advanced flow channel structures are obtained using topology optimization algorithms. Topology optimization algorithms are mathematical optimization methods that can calculate the optimal flow channel layout based on given boundary conditions, load conditions, and heat transfer objectives. For example, for power batteries during high-power discharge (first operating state) and low-power standby (second operating state), due to the different heat generation conditions, topology optimization algorithms can obtain corresponding cooling flow channel diagrams for each.

[0042] This application also uses a topology optimization algorithm to obtain cooling flow channel diagrams for multiple different operating states of a single power battery. Then, a liquid cooling plate with a variable flow channel structure is used to fit these cooling flow channel diagrams for better heat exchange. The variable flow channel structure liquid cooling plate provided in this application is applied to power batteries, including the following steps:

[0043] First, step 1: Using a topology optimization algorithm, obtain the cooling channel diagrams for the first and second operating states of the power battery, denoted as the first cooling channel diagram and the second cooling channel diagram, respectively. For example... Figure 2 The diagram shows the cooling flow path of the power battery in its first operating state. The black filled areas represent areas where coolant cannot flow, indicating obstructions, while the white areas represent the flow path areas.

[0044] The next step is step 2, which requires determining which of the variable flow channel components 3 on the first surface layer 1 of the liquid cooling plate need to deform and extend. These variable flow channel components 3 are designated as the first deformation group. The extended variable flow channel components 3 combine to form a blocking section, used to block or divide the cooling fluid. The variable flow channel components 3 between opposing blocking sections do not extend and remain flush with the surface of the first surface layer 1. These areas are recessed areas for the blocking sections, and the recessed areas form flow channels.

[0045] Step 2 further includes the following sub-steps, such as Step 2.1 to Step 2.4.

[0046] Step 2.1: Mesh the first cooling channel diagram according to the continuous mesh pattern of the liquid cooling plate. Assuming the rectangular array mesh of the liquid cooling plate is m×n, then divide the first cooling channel diagram into m×n corresponding mesh regions, such as... Figure 3 As shown. After the cooling channel pattern falls into each grid, a single grid may contain only obstructions, only flow channels, or both. The variable flow channel component 3 within the grid corresponding to the liquid cooling plate with its variable flow channel structure is the location that needs to be deformed.

[0047] The key is to determine how to identify these variable flow channel components 3, and to operate according to the following steps 2.2.

[0048] Step 2.2: Measure and calculate the projected area of ​​the flow channel region in the first cooling flow channel diagram falling within the corresponding grid. The projected area of ​​the flow channel within each grid can be accurately measured and calculated using image processing software or a dedicated calculation program.

[0049] Then, select the variable flow channel component 3 that needs to be deformed according to the rule in step 2.3.

[0050] Step 2.3: When the projected area of ​​the flow channel within a grid is less than half the total area of ​​the grid, the telescopic column of that grid belongs to the first deformation group. For example, if the area of ​​a grid is A, and the projected area of ​​its internal flow channel is a, when a / A < 1 / 2, the telescopic column at the corresponding grid position is determined to be part of the first deformation group. All first deformation groups define the edge structure of the blocking part, such as... Figure 4 As shown.

[0051] The interior of the blocking section can be "solid," in which case all variable flow channel components 3 constituting the blocking section extend outwards. Alternatively, the interior of the blocking section can be "hollow," in which case the internal variable flow channel components 3 do not need to extend outwards, reducing the number of variable flow channel components 3 that need to be operated. These internal variable flow channel components 3 are selected according to the rules in step 2.4.

[0052] Step 2.4: Please combine Figure 5 As shown, when the channel projection area within a grid is zero and the channel projection area of ​​each of the eight grids directly adjacent to that grid is less than half the area of ​​a single grid, the telescopic columns of that grid do not belong to the first deformation group. This is a special case, clarifying that in grid locations without channel projection, the telescopic columns do not participate in the channel construction of the power battery's first operating state, and these telescopic columns are not at or near the edge of the blocking section, thus the edge of the blocking section formed by the telescopic columns has a certain width. According to the above screening rules, telescopic columns that do not belong to the first deformation group are selected inside the blocking section, such as... Figure 6 As shown within the dashed box.

[0053] Based on steps 2.3 and 2.4 above, the deformed state of the telescopic column in the first deformation group is obtained, as follows: Figure 7 As shown within the dashed box, the blocking section is formed by the extension of a telescopic column, and the edge of the blocking section is at least one grid width wide. Figure 7 Black squares represent extended telescopic columns, and white squares represent non-extended telescopic columns. The method for determining the second deformation group is the same as that for determining the first deformation group. The second cooling channel diagram is compared with the liquid cooling plate in the initial state. Following a method similar to steps 2.1 to 2.4 above, the telescopic columns that the liquid cooling plate needs to extend in the second working state of the power battery are determined and denoted as the second deformation group.

[0054] After the above preliminary work is completed, the variable liquid cooling plate will be installed on the power battery and configured accordingly.

[0055] When the power battery is in the first working state, all the telescopic columns of the first deformation group extend and the remaining telescopic columns retract. At this time, the flow channel shape inside the liquid cooling plate fits the first cooling flow channel diagram, which can provide efficient heat exchange for the power battery in the first working state.

[0056] When the power battery is in the second working state, all the telescopic columns of the second deformation group extend, and the remaining variable flow channel components 3 retract, so that the flow channel of the liquid cooling plate fits the second cooling flow channel diagram to meet the heat exchange requirements of the power battery in the second working state.

[0057] For example, in practical applications, sensors monitor the operating status of the power battery in real time. When the battery is detected to be in a high-power discharge first operating state, the control system, according to preset instructions, drives the telescopic columns of the first deformation group to extend, creating corresponding cooling channels to ensure that the coolant can efficiently remove heat. When the power battery switches to a low-power standby second operating state, the control system retracts all the telescopic columns of the first deformation group and then extends all the telescopic columns of the second deformation group, adjusting the channel structure to meet the heat exchange requirements at this time. When the telescopic columns of the first and second deformation groups overlap, these telescopic columns remain stationary during the transition from the first to the second operating state.

[0058] Through in-depth analysis of topology optimization results under different operating conditions, the state of mesh regions that consistently remain in a solid or fluid state under all conditions can be fixed. These regions either always feature non-deformable flow channel components or omit flow channel components in certain specific meshes. This simplifies the structural adjustment process, reduces unnecessary adjustments, and improves response speed. Furthermore, it enhances the stability and reliability of the structure. For example, some meshes far from the core heat-generating area of ​​the battery, regardless of the operating condition, have little impact on the overall cooling effect as either fluid or solid regions, and their state remains consistent. Therefore, their state can be fixed to avoid repeated adjustments when switching between different operating conditions.

[0059] Furthermore, for areas particularly sensitive to cooling performance, this invention proposes altering the size of the local mesh to achieve mesh divisions of varying resolutions. Using smaller meshes in these critical areas allows for more refined optimization. For instance, in areas of the battery pack prone to localized high temperatures, reducing the mesh size—for example, dividing a mesh into quarters or ninths—allows for more precise control of the flow channel edge shape, resulting in smoother and more efficient coolant flow in those areas, thus achieving superior thermal management. These improvements enable optimal battery thermal management under various operating conditions, effectively enhancing the performance and safety of the power battery system under diverse circumstances.

Claims

1. A liquid cooling plate with a variable flow channel structure, characterized in that, It includes a first surface layer, a second surface layer, and a flow channel layer sandwiched between the first surface layer and the second surface layer; The first surface layer is provided with variable flow channel components arranged in a continuous grid, and each variable flow channel component is in close contact with the adjacent variable flow channel component; The variable flow channel component is configured such that each component can deform independently, and several variable flow channel components are combined after deformation to form a flow channel layer that adapts to a certain heat exchange condition. The variable flow channel component adopts a telescopic column, and the telescopic column's extension and retraction direction is perpendicular to the first surface layer. By extending and retracting different telescopic columns, flow channels of different shapes are constructed between the first surface layer and the second surface layer.

2. The liquid cooling plate with variable flow channel structure according to claim 1, characterized in that, The continuous grid is arranged in a rectangular grid array.

3. The liquid cooling plate with variable flow channel structure according to claim 2, characterized in that, The side length of a single variable flow channel component is less than one-fiftieth of the shortest side length of the liquid cooling plate.

4. The liquid cooling plate with variable flow channel structure according to claim 1, characterized in that, When the liquid cooling plate is in its initial state, all telescopic columns retract into the first surface layer.

5. The liquid cooling plate with variable flow channel structure according to claim 4, characterized in that, When the telescopic column retracts into the first surface layer, the top surface of the telescopic column does not extend beyond the inner surface of the first surface layer.

6. The liquid cooling plate with variable flow channel structure according to claim 4, characterized in that, When the telescopic column extends into the second surface layer, the top surface of the telescopic column contacts the inner surface of the second surface layer.

7. The liquid cooling plate with variable flow channel structure according to claim 4, characterized in that, The telescopic column is extended and retracted by means of an electric motor, electromagnetic or hydraulic control.

8. A method for applying a liquid cooling plate with a variable flow channel structure, characterized in that, Applying the liquid cooling plate with variable flow channel structure as described in claim 4 to a power battery includes the following steps: Step 1: Based on the topology optimization algorithm, obtain the cooling flow channel diagrams of the first and second operating states of the power battery, which are the first cooling flow channel diagram and the second cooling flow channel diagram, respectively. Step 2: Compare the first cooling channel diagram with the liquid cooling plate in the initial state to obtain the telescopic column that the liquid cooling plate with variable channel structure needs to extend for the first time, which is denoted as the first deformation group. Step 3: Compare the second cooling channel diagram with the liquid cooling plate in the initial state to obtain the telescopic column that the liquid cooling plate with variable channel structure needs to extend for the second time, which is denoted as the second deformation group; Step 4: The variable flow channel structure liquid cooling plate is installed on the power battery and configured such that: when the power battery is in the first working state, all the telescopic columns of the first deformation group extend and the remaining telescopic columns retract, in order to fit the first cooling flow channel diagram; when the power battery is in the second working state, all the telescopic columns of the second deformation group extend and the remaining telescopic columns retract, in order to fit the second cooling flow channel diagram.

9. The application method of the liquid cooling plate with variable flow channel structure according to claim 8, characterized in that, Step 2 includes the following sub-steps: Step 2.1: Mesh the first cooling channel diagram according to the continuous mesh pattern of the liquid cooling plate with variable flow channel structure; Step 2.2: Measure and calculate the projected area of ​​the flow channel region in the first cooling flow channel diagram that falls into the corresponding grid; Step 2.3: When the projected area of ​​the flow channel within the grid is less than half of the total area of ​​the grid, the telescoping column of the grid belongs to the first deformation group.

10. The application method of the liquid cooling plate with variable flow channel structure according to claim 9, characterized in that, Step 2 also includes the following steps: Step 2.4: When the projected area of ​​the flow channel in the grid is zero, and the projected area of ​​each flow channel in the eight grids directly adjacent to the grid is less than half the area of ​​a single grid, the telescopic column of the grid does not belong to the first deformation group.

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