Battery Coolant Manifold Layout for Stable Multi-Circuit Flow
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Solution Overview
Problem
Existing vehicle battery cooling systems face issues with flow disturbances, such as backflows and zero flow situations, due to different pressure drops and separate coolant demands in multiple circuits, which can damage components and reduce efficiency, while also occupying valuable space and being costly to manufacture.
Innovation Solution
A coolant distribution manifold with a receiving section, supplying section, and deairing section, allowing for individual control of coolant flow and temperature to each circuit from a common reservoir, reducing flow disturbances and optimizing space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If multiple coolant circuits are used to cool different battery packs, then temperature regulation capability is improved, but flow disturbances such as backflows and zero flow situations occur due to different pressure drops
Solution Approach 1:
The patent merges multiple coolant circuits into a single integrated cooling system with a common coolant distribution manifold. This allows all battery packs to be cooled through a unified circuit architecture, eliminating the flow disturbances that occur when multiple separate circuits operate independently with different pressure drops.
Solution Approach 2:
The coolant distribution manifold acts as an intermediary component that receives coolant from the temperature conditioning circuit and distributes it to multiple battery packs. This mediator ensures uniform coolant distribution and prevents backflows by providing a centralized pressure equalization point.
2Adaptability or versatility
If separate coolant circuits are used for each battery pack, then individual temperature control is improved, but the system complexity and manufacturing cost increase
Solution Approach 1:
The cooling system is segmented into functional modules: a temperature conditioning circuit for centralized temperature control, a coolant distribution manifold for unified coolant allocation, and individual cooling channels for each battery pack. This segmentation allows individual temperature control while maintaining system simplicity through standardized modular components.
Solution Approach 2:
The coolant distribution manifold serves multiple functions simultaneously: it distributes coolant to various battery packs, equalizes pressure across circuits, provides a deairing section for air removal, and acts as a centralized control point. This multi-functionality reduces the need for separate components, thereby reducing system complexity.
3Productivity
If multiple coolant pumps are arranged in the same cooling system, then coolant flow control is improved, but air entrapment and deairing problems occur in the coolant circuits
Solution Approach 1:
The deairing section is positioned at the highest point of the coolant distribution manifold, allowing air bubbles to naturally rise and be removed before coolant is distributed to the battery packs. This preliminary air removal prevents air entrapment in the cooling circuits before the coolant reaches the pumps and battery cooling channels.
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 provides efficient temperature regulation and deairing of coolant circuits, minimizing flow disturbances and space usage, while being cost-effective to manufacture and assemble.
Implementation Method 1
a coolant distribution manifold (1) for a vehicle propulsion battery cooling system... The coolant distribution manifold comprises a coolant inlet configured to receive coolant from the temperature conditioning circuit
Implementation Method 2
a receiving section configured to receive coolant from the at least two coolant circuits... allowing for an individual control of the flow rate through each one of the at least two coolant circuits without any significant risk of flow disturbances, such as back flows
Implementation Method 3
a supplying section configured to supply coolant to the at least two coolant circuits... individual control of the flow rate through each one of the at least two coolant circuits
Implementation Method 4
a temperature conditioning circuit (11)... configured to cool a respective set of propulsion battery cells
Implementation Method 5
the deairing of the coolant circuits can be problematic... air inside a coolant circuit reduces the efficiency of the coolant circuit
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A coolant distribution manifold (1) for a vehicle propulsion battery cooling system (3) is disclosed. The coolant distribution manifold (1) comprises a coolant inlet (13) configured to receive coolant from a temperature conditioning circuit (11), a receiving section (5) configured to receive coolant from at least two propulsion battery coolant circuits (c1, c2, c3, 5 c4, c5), and a supplying section (7) configured to supply coolant to the at least two coolant circuits (c1, c2, c3, c4, c5). The supplying section (7) is arranged downstream of the coolant inlet (13) and of the receiving section (5). The present disclosure further relates to a vehicle propulsion battery cooling system (3), and a vehicle (2).