Battery Module Coolant Flow Optimization via Variable Hole Sizing
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Solution Overview
Problem
Current thermal management systems for energy-storage modules in electric vehicles face inefficiencies due to thermal imbalance among battery cells and uneven coolant fluid flow, leading to temperature variations and reduced module lifespan.
Innovation Solution
The implementation of a coolant fluid distribution system with varying hole sizes and pressure zones in the cell ducts to optimize coolant fluid flow, ensuring consistent temperatures across energy-storage cells by adjusting fluid flow rates and pressures based on cell location and distance from the coolant inlet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If coolant fluid is distributed uniformly to all cells, then the cooling system is simple to manufacture, but thermal imbalance occurs among battery cells leading to temperature variations
Solution Approach 1:
The cell ducts are designed with varying hole sizes at different locations to provide localized cooling adjustments. Cells closer to the coolant inlet receive coolant through smaller holes, while cells farther away receive coolant through larger holes, compensating for the reduced coolant pressure and flow at distant locations. This local variation in hole size ensures uniform temperature distribution across all cells despite the simple overall system structure.
2Temperature
If coolant fluid flow rate is increased to cool all cells effectively, then temperature control improves, but pressure losses increase and system efficiency decreases
Solution Approach 1:
The system changes the physical parameter of hole size in the cell ducts to optimize coolant flow distribution. By varying the hole dimensions based on location, the system achieves effective cooling at all cell positions without requiring excessive coolant flow rates. This parameter adjustment compensates for pressure losses naturally occurring in the system, maintaining cooling efficiency while minimizing energy waste.
3Temperature
If cells are positioned closer to the coolant inlet for better cooling, then cooling efficiency improves, but thermal imbalance increases among cells at different distances
Solution Approach 1:
The cell ducts incorporate asymmetric hole size distribution rather than uniform holes. Cells positioned farther from the coolant inlet are served by larger holes, while cells nearer the inlet use smaller holes. This asymmetric design compensates for the natural gradient in coolant pressure and temperature along the flow path, ensuring that all cells operate within optimal temperature ranges regardless of their position relative to the inlet.
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 approach maintains energy-storage module temperatures within a narrow range, reducing thermal stress and extending the module's lifespan by ensuring even cooling across all cells.
Implementation Method 1
coolant fluid passes through the coolant fluid inlet into the cavity and through the plurality of holes to the plurality of cells to reduce a temperature of each of the plurality of cells
Data Source
AI summary
In one aspect, an apparatus for storing energy comprises an enclosure including a coolant fluid inlet configured to couple to a coolant fluid system, a plurality of energy-storage cells housed in an arrangement within the enclosure, and a cell holder. The cell holder has retaining features configured to hold the plurality of cells in the arrangement, a first surface forming a cavity between the cell holder and an adjacent wall of the enclosure and a plurality of holes that pass from the cavity through the cell holder and to the region of the enclosure housing the plurality of energy-storage cells. The coolant fluid inlet is in fluid communication with the cavity. Each of the holes is positioned proximate to a cell. Coolant fluid passes through the coolant fluid inlet into the cavity and through the holes to the cells to reduce a temperature of each of the cells.