Multilayer Battery Case with Phase-Change Thermal Management
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Solution Overview
Problem
Existing battery cooling systems for electric vehicles consume excessive energy, especially when the vehicle is stopped in high-temperature environments, as they require fans and air conditioning to maintain battery temperature, leading to reduced battery life.
Innovation Solution
A battery case with a multilayer structure comprising a metal layer, a heat-insulating layer, and a phase-change heat storage layer, combined with a heat transport device featuring a natural refrigerant circulation system without the need for pumps or power supplies, effectively managing battery temperature without significant energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a fan is driven to cool the battery, then the battery temperature is reduced, but the energy consumption increases
Solution Approach 1:
The battery case structure enables passive cooling through natural convection and radiation without requiring active fan operation. The multilayer design with heat insulating material and heat dissipation protrusions allows the battery to self-regulate temperature using environmental temperature differences, eliminating the need for continuous fan operation and reducing energy consumption.
Solution Approach 2:
The battery case is divided into multiple functional layers: an inner case with heat insulating material, an outer case with heat dissipation protrusions, and vacuum insulation layers. This segmentation allows different regions to perform specialized functions (insulation vs. heat dissipation), enabling effective temperature management without requiring high-energy active cooling systems.
2Temperature
If air conditioning refrigerant is used to cool the battery when outside temperature is higher, then the battery temperature is maintained, but the energy consumption increases and the battery cannot be cooled when the vehicle is stopped
Solution Approach 1:
The heat insulating material is pre-installed within the battery case structure, creating a thermal barrier before heat transfer occurs. This preliminary insulation layer prevents heat from the external environment from readily reaching the battery, reducing the need for active cooling even when the vehicle is stopped in high-temperature conditions.
Solution Approach 2:
The battery case employs localized heat dissipation protrusions on the outer case that create targeted heat dissipation pathways. These protrusions concentrate heat transfer at specific locations where natural convection currents can efficiently carry heat away, providing effective cooling without requiring system-wide air conditioning.
3Ease of manufacture
If the battery is housed in a simple case structure, then the manufacturing cost is low, but the temperature management capability is insufficient
Solution Approach 1:
The battery case uses a nested structure where the inner case containing the battery is placed within the outer case, with vacuum insulation layers between them. This nested design provides advanced thermal management capabilities while maintaining a compact form factor and using straightforward manufacturing processes for each individual case component.
Solution Approach 2:
The battery case combines different materials with complementary thermal properties: heat insulating material (such as foam or air gaps) for thermal isolation and heat dissipation protrusions (metal or conductive material) for targeted heat release. This composite approach achieves superior temperature management using commonly available materials and standard manufacturing techniques.
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
This solution significantly reduces energy consumption for cooling the battery, prolongs battery life by maintaining optimal temperatures, and prevents overheating even when the vehicle is stationary in high-temperature conditions.
Implementation Method 1
a third layer which is closer to the battery than the second layer is, and is made of phase-change heat storage material
Implementation Method 2
a third layer which is closer to the battery than the second layer is, and is made of phase-change heat storage material
Implementation Method 3
a second layer which is closer to the battery than the first layer is, and is made of heat insulating material
Implementation Method 4
a first layer which is made of metal
Data Source
AI summary
A battery case within which a battery is housed includes a first layer that is made of metal, a second layer that is made of heat insulating material, and a third layer that is made of phase-change heat storage material. The second layer is closer to the battery than the first layer is. The third layer is closer to the battery than the second layer is.