Liquid-cooled battery thermal management system with wavy lines

Abstract

A liquid-cooled battery thermal management system with two rectangular flow channels and hemispherical waves on the inner and outer surfaces to improve heat transfer efficiency.

Description

Application area of ​​the invention

[0001] The invention relates to the field of battery systems for electric vehicles, in particular thermal management devices that utilize liquid cooling channels with corrugated surfaces to improve heat dissipation, increase energy efficiency and ensure safe battery operation under various load conditions. Background of the invention

[0002] With the increasing prevalence of electric vehicles (EVs), efficient thermal management of lithium-ion batteries has become a key challenge in battery design. Battery cells generate significant amounts of heat during charging and discharging, and excessively high temperatures can impair performance, shorten lifespan, and pose safety risks. Conventional cooling systems with flat flow channels or air cooling often fail to ensure uniform temperature distribution within the densely packed cylindrical cells. Flat channels limit the heat transfer surface area and create laminar flow, resulting in insufficient cooling performance. Furthermore, uneven temperature gradients can lead to cell imbalances and compromise the overall reliability of the battery pack.To solve these problems, an advanced cooling system is required that improves heat transfer while ensuring compactness, structural integrity and compatibility with existing EV battery configurations. Summary of the invention

[0003] The present invention relates to a liquid-cooled battery thermal management system with two rectangular cooling channels whose inner and outer surfaces have hemispherical corrugations. The inner corrugations generate turbulent flow conditions that increase the convective heat transfer coefficient and thus significantly improve heat dissipation from the battery surfaces. At the same time, the outer corrugations enable additional convective cooling by the ambient air and thus contribute to multimodal heat dissipation.

[0004] The system is designed for flexible operation and allows the use of different coolants or variable flow rates in separate channels for individual temperature control. This modular arrangement ensures adaptive control under various driving and environmental conditions, resulting in improved battery safety, higher energy efficiency, and a longer service life. The innovative structure combines high thermal performance with mechanical strength, making it ideal for integration into modern electric vehicles without compromising on space requirements or weight. Detailed description

[0005] The invention comprises a modular cooling device that can be positioned alongside cylindrical lithium-ion battery cells in an array. The device consists of two parallel, rectangular channels made of thermally conductive materials such as aluminum or copper alloys, which ensure efficient heat exchange between the coolant and the battery surfaces. Each channel has an inner and outer surface featuring a series of hemispherical waves that increase turbulence and enlarge the surface area.

[0006] The internal wave structures disrupt the laminar flow of the coolant, generating local micro-vortices that improve mixing and heat exchange. These waves also distribute the coolant evenly along the battery array, reducing the risk of localized overheating. The outer wave structures, exposed to ambient air or integrated air ducts, provide an additional convective cooling effect by increasing the surface area.

[0007] The system allows the use of two different coolants in the two channels. For example, a water-ethylene glycol mixture can circulate in one channel, while a dielectric coolant is used in the other, depending on the thermal requirements. This flexibility, achieved through the use of two coolants, enables the system to adapt to varying heat loads and environmental conditions. Furthermore, the flow rate can be variably controlled by sensors and a feedback pump system, allowing the cooling intensity to be dynamically adjusted based on real-time battery temperature data.

[0008] A thermal management controller, in conjunction with temperature sensors integrated into the battery, regulates the coolant flow, direction, and rate. Using predictive algorithms, the controller detects temperature spikes during acceleration or charging and proactively increases coolant circulation in critical areas. This closed-loop control system ensures a uniform battery temperature across all cells.

[0009] The corrugated channels are integrated into a lightweight frame that provides both mechanical protection and thermal insulation. Precise welding or bonding minimizes the risk of coolant leaks, and seals are used at the connection points. The modular design allows for easy maintenance and replacement without requiring complete battery disassembly.

[0010] To further enhance performance, the system can be combined with phase change materials (PCMs) or thermoelectric modules to compensate for temperature fluctuations under peak load conditions. These hybrid configurations enable improved energy recovery and higher overall vehicle efficiency. The compact structure of the corrugated channels also allows them to be stacked or bent to adapt to various battery module geometries, thus offering design flexibility for diverse electric vehicle models.

[0011] Experimental results have shown that corrugated fluid channels, compared to smooth channels, enable up to a 35% improvement in the heat transfer coefficient while maintaining acceptable pressure drop values. This ensures effective cooling without excessive pump power consumption and thus contributes to the overall energy savings of the vehicle.

Claims

[1] A liquid cooling-based battery thermal management system with two rectangular flow channels and hemispherical waves on the inner and outer surfaces to improve heat transfer efficiency. [2] System according to claim 1, wherein internal waves generate a turbulent flow to improve the convective heat dissipation from adjacent cylindrical lithium-ion battery cells. [3] System according to claim 1 or 2, wherein the outer waves promote additional convective cooling by ambient airflow over the outer surface of the channels. [4] System according to one of the preceding claims, wherein the two channels operate with different coolants or adjustable flow rates to enable individual and adaptive thermal management of the battery.