Battery Thermal Management with Zoned Coolant Flow for Fast Charging
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Solution Overview
Problem
Existing battery thermal management systems for electric vehicles face challenges in efficiently managing heat during charging and discharging, which can lead to thermal events that disrupt power delivery and potentially damage batteries or vehicles.
Innovation Solution
A battery thermal management system that includes a battery pack, a circulation subsystem with a pump and fluid manifold, and a heat exchange system, which circulates a working fluid to manage temperature distribution within the battery pack and prevent thermal events.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If fast charging is implemented to improve charging speed, then charging efficiency is improved, but heat generation increases leading to thermal management challenges
Solution Approach 1:
The battery pack is divided into multiple temperature zones with independent thermal management control. Each zone has its own heating/cooling channels that can be independently controlled, allowing selective thermal management of different battery regions based on their specific thermal needs during fast charging operations
Solution Approach 2:
The system dynamically adjusts thermal management parameters (heating/cooling flow rates, temperatures) based on real-time battery state monitoring. During fast charging, the system modifies coolant flow rates and temperatures to optimize heat removal while maintaining charging speed, preventing thermal runaway through adaptive parameter control
2Reliability
If thermal management system complexity is increased to improve temperature control, then thermal management effectiveness is improved, but system weight and complexity increase
Solution Approach 1:
The thermal management system is designed to perform multiple functions using a unified architecture. The same coolant circulation system provides both heating and cooling capabilities, and the fluid manifold serves both thermal regulation and structural support functions, reducing overall system complexity while maintaining effective temperature control
Solution Approach 2:
Multiple thermal management functions (heating, cooling, temperature monitoring, fluid distribution) are merged into an integrated system architecture. The heating and cooling channels are combined in a single fluid manifold structure, and temperature sensors are integrated directly into the battery pack assembly, reducing the number of separate components and simplifying system implementation
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 effectively manages thermal states within the battery pack, preventing thermal runaway and ensuring optimal power delivery, while also enabling rapid charging and reducing weight and complexity in vehicle systems.
Implementation Method 1
a circulation subsystem with a pump and fluid manifold, and a heat exchange system, which circulates a working fluid to manage temperature distribution within the battery pack
Implementation Method 2
a heat exchange system, which circulates a working fluid to manage temperature distribution within the battery pack
Data Source
Figure 1~2
Figure 3A~3B
Figure 4
AI summary
The battery thermal management system includes a battery pack, a circulation subsystem, and a heat exchanger. The system can optionally include a cooling system, a reservoir, a de-ionization filter, a battery charger, and a controller.