Vehicle Battery Pack Cooling System with Double Filter and Magnetic Dust Removal
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Solution Overview
Problem
Existing cooling systems for vehicle battery packs face inefficiencies due to dust accumulation, which reduces cooling efficiency and can cause malfunctions or short circuits, especially with metal dust, and require frequent and expensive filter replacements.
Innovation Solution
A double filter system is implemented at the air inlet, comprising a pre-filter with large air holes for frequent replacement and a medium filter with small air holes for less frequent replacement, along with a magnetic force to collect metal dust, reducing the risk of malfunctions and improving cooling efficiency without the need for bulky intake ducts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a single filter is mounted at the air inlet to remove dust, then dust removal is achieved, but the filter requires frequent replacement and has high operational costs
Solution Approach 1:
The filter system is divided into two separate filters: a pre-filter with large air holes for frequent replacement and a medium filter with small air holes for less frequent replacement. This segmentation allows each filter to perform its specific function optimally, with the pre-filter capturing larger particles and the medium filter capturing finer particles, thereby extending the overall filter replacement cycle and reducing operational costs.
2Object-affected harmful factors
If a filter with small air holes is used to remove fine dust and metal particles, then dust removal efficiency is improved, but the filter requires frequent replacement
Solution Approach 1:
The filtering function is segmented into two stages: the pre-filter with large air holes handles frequent particle capture and can be replaced often, while the medium filter with small air holes handles fine dust and metal particles less frequently. This segmentation allows the medium filter to maintain high dust removal efficiency without requiring frequent replacement, as the pre-filter protects it from rapid clogging.
Solution Approach 2:
The pre-filter performs preliminary filtration by capturing larger particles first, which protects the medium filter from rapid accumulation of dust. This preliminary action extends the service life of the medium filter, allowing it to focus on removing fine dust and metal particles without being quickly saturated by larger particles.
3Temperature
If air from outside the vehicle is used for cooling, then cooling is achieved, but dust accumulation on battery components occurs
Solution Approach 1:
The double filter system acts as an intermediary between the outside air and the battery pack. The pre-filter and medium filter together form a protective barrier that allows cooling air to pass through while blocking dust particles, including metal dust, from entering the battery components. This intermediary structure enables the use of outside air for cooling without the harmful effects of dust accumulation.
4Productivity
If metal dust is not removed from the cooling air, then cooling efficiency is maintained, but malfunction or short circuits of the battery pack may occur
Solution Approach 1:
The medium filter with small air holes serves as a protective intermediary that specifically captures metal dust particles from the cooling air. This allows the cooling system to maintain efficiency by using outside air while preventing metal dust from reaching electrical connecting parts and circuit boards, thereby ensuring battery pack reliability and preventing malfunctions or short circuits.
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 double filter system effectively extends filter replacement cycles, reduces operational costs, and prevents malfunctions by efficiently filtering dust and metal particles, enhancing cooling efficiency and compactness of the cooling system.
Implementation Method 1
a pre-filter having high frequency of replacement and a medium filter having low frequency of replacement, which are successively mounted at an air inlet part
Implementation Method 2
along with a magnetic force to collect metal dust
Data Source
AI summary
Disclosed herein is a cooling system for vehicle battery packs, including a double filter device mounted at an air inlet part, through which air for cooling the battery pack is introduced from the outside and/or the inside of the vehicle. The double filter includes a pre-filter having relatively large air holes, the pre-filter having high frequency of replacement, and a medium filter having relatively small air holes, the medium filter having low frequency of replacement. The pre-filter is located before the medium filter in the direction in which the air is introduced. Consequently, dust is removed from air, and therefore, the cooling efficiency of the battery pack is increased. In a preferred structure, metal dust is also effectively removed by the magnetic force applied to the medium filter. Consequently, the malfunction or short circuits of the battery pack are prevented. Also, air surrounding the battery pack is directly introduced through the through-type intake ports without passing through any pipe-shaped intake duct. Consequently, generation of noise, which is a problem caused when air in the cabin is used, and backward flow of flames and toxic gas, which are generated during a fire, are prevented. Furthermore, the battery pack is constructed in a compact structure.