Battery Box Thermal Management Using Segmented Phase Change Materials
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Solution Overview
Problem
Electric vehicle battery cells face challenges in maintaining optimal temperature ranges for efficient operation, preventing damage from shocks, and managing thermal energy effectively, while existing solutions either focus on active cooling or lack comprehensive thermal management.
Innovation Solution
A battery box with an aluminum hollow profile filled with at least two phase change materials (PCMs) that absorb and release heat to maintain optimal temperature ranges, utilizing a corrugated pattern to enhance thermal conductivity and contact area, and strategically positioning chambers for efficient thermal buffering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single phase change material is used in the battery box, then the thermal management system is simple, but it cannot maintain optimal temperature across different operating conditions
Solution Approach 1:
The battery box is divided into multiple compartments, each filled with a different phase change material having specific melting points (e.g., 25°C and 45°C). This segmentation allows each compartment to handle specific temperature ranges, enabling comprehensive thermal management across different operating conditions while keeping each individual compartment relatively simple
Solution Approach 2:
Different regions of the battery box are assigned different phase change materials based on local thermal management needs. The first phase change material (lower melting point) handles cooling during moderate operation, while the second phase change material (higher melting point) activates during high-temperature conditions, providing localized thermal responses tailored to specific operating scenarios
2Reliability
If multiple phase change materials are used to improve thermal management, then temperature control improves, but the device complexity increases
Solution Approach 1:
Multiple phase change materials are merged into a single integrated battery box structure with multiple compartments. The aluminum alloy housing combines structural support with thermal management functions, while the phase change materials are integrated directly into the box compartments, eliminating the need for separate cooling systems and reducing overall device complexity despite the advanced thermal management capability
Solution Approach 2:
The battery box serves multiple functions simultaneously: it provides structural support for the battery cells, acts as a thermal management system through phase change materials, and offers protection against external impacts. The aluminum alloy material provides both mechanical strength and thermal conductivity, while the phase change materials provide both cooling and heat storage functions across different temperature ranges
3Weight of moving object
If aluminum hollow profile is used for the battery box, then weight is reduced, but structural strength may be compromised
Solution Approach 1:
The battery box uses thin-walled aluminum alloy hollow profiles that provide adequate structural strength while minimizing weight. The hollow structure acts as a moment of inertia element, providing crash protection without requiring thick walls. The thin walls are sufficient for thermal management contact while keeping the overall weight low for electric vehicle application
Solution Approach 2:
The battery box combines aluminum alloy material with phase change materials to create a composite thermal management system. The aluminum alloy provides structural strength and thermal conductivity, while the phase change materials provide thermal buffering. This composite approach allows thin-walled construction that is both strong and lightweight, as the phase change materials provide additional functional value without requiring heavy structural reinforcement
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively regulates battery cell temperatures, preventing overheating and undercooling, thereby extending battery life and ensuring operational integrity without increasing weight or complexity.
Implementation Method 1
at least one chamber of said aluminium hollow profile is filled with a first phase change material having a melting point T1F and a second chamber is filled with a second phase change material having a melting point T2F
Implementation Method 2
phase change materials (PCMs) that absorb and release heat to maintain optimal temperature ranges
Implementation Method 3
utilizing a corrugated pattern to enhance thermal conductivity and contact area
Data Source
AI summary
A battery box, supporting structure and insuring thermal management of one or more battery cells allowing a temperature control of said battery cells environment to insure its optimal operational condition, the battery box comprises at least one aluminum hollow profile, wherein said aluminium hollow profile comprises at least two chambers, wherein at least one chamber is filled with a first phase change material having a melting point T1F and at least one chamber is filled with a second phase change material having a melting point T2F, where T1F>T2F.