Dual-Source Battery Cold Plate Cooling for Temperature Uniformity
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Solution Overview
Problem
Current battery thermal management systems face challenges with low cooling efficiency, high energy consumption, complex structure, and poor temperature uniformity, which affect battery performance and safety.
Innovation Solution
A dual cooling source direct expansion liquid cooling system combining air-cooling and liquid-cooling systems, controlled by three-way valves, utilizing phase-change thermostatic materials and energy storage units to adapt to outdoor temperature, ensuring flexible temperature regulation and energy efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If air-cooled cooling is used, then the structure is simple, but the cooling efficiency is low and energy consumption is high
Solution Approach 1:
The system is divided into two independent cooling paths: air-cooling system and liquid-cooling system. Each path can operate independently or in combination, allowing the system to select the most efficient cooling method based on thermal demand while maintaining structural simplicity through modular design
Solution Approach 2:
The cooling system is designed to perform multiple functions through a single integrated structure that can switch between air-cooling and liquid-cooling modes. The shared components (pumps, valves, heat exchangers) serve dual purposes, reducing overall system complexity while providing high-efficiency liquid cooling when needed
2Productivity
If cold plate liquid cooling technology is used, then the cooling efficiency is improved, but the structure becomes complex and temperature uniformity deteriorates
Solution Approach 1:
Phase change thermostatic material is introduced as an intermediary between the battery packs and the liquid cooling system. This material absorbs heat through phase change, providing thermal buffering that improves temperature uniformity across battery cells while reducing the complexity of the liquid cooling distribution network
Solution Approach 2:
The system utilizes phase change thermostatic material that transitions between solid and liquid phases at specific temperature ranges. This phase change mechanism provides passive thermal regulation, improving temperature uniformity without requiring complex active control systems or additional structural components
3Device complexity
If single cooling system is used, then the structure is simple, but the adaptability to different temperature conditions deteriorates
Solution Approach 1:
The system incorporates dynamic switching capability between air-cooling and liquid-cooling modes through controllable valves and pumps. The system automatically adjusts the cooling path based on real-time temperature conditions, battery thermal demand, and environmental factors, providing high adaptability while maintaining relatively simple system configuration through centralized control
Solution Approach 2:
The system includes self-regulating components such as thermostatic expansion valves and temperature-sensitive control mechanisms that automatically adjust cooling parameters without external intervention. This self-service capability enhances adaptability to varying temperature conditions while avoiding the need for complex external control systems
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 system reduces energy consumption, ensures safe and stable battery operation, maintains temperature uniformity, and provides emergency cooling, while being easy to install and maintain.
Implementation Method 1
the cold plate is provided with a heat exchanger tube and phase change thermostatic material through the cold plate; the phase change thermostatic material is used to absorb the heat from the battery packs
Implementation Method 2
the phase change thermostatic material is used to absorb the heat from the battery packs
Implementation Method 3
the liquid refrigerant that enters the heat exchanger tube is changed into a gaseous refrigerant
Implementation Method 4
the liquid refrigerant that enters the heat exchanger tube is changed into a gaseous refrigerant
Implementation Method 5
the cold plate is provided with a heat exchanger tube and phase change thermostatic material through the cold plate
Data Source
AI summary
A dual cooling source direct expansion liquid cooling system for battery energy storage and a control method. The system includes an air conditioning and refrigeration system, a battery management system and a control system; the battery management system includes a plurality of battery packs and a cold plate provided in correspondence with the battery packs; the battery pack is in direct contact with the cold plate for heat exchange; the cold plate is provided with a heat exchanger tube running through the cold plate and a phase change thermostatic material; the phase change thermostatic material is used to absorb heat from the battery pack and change the liquid refrigerant phase into gaseous refrigerant entering the heat exchanger tube; the heat exchanger tube output end of the cold plate is connected to the air conditioning and refrigeration system via an intermediate system.