Battery Module Cooling Valves for Thermal Runaway Mitigation
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Solution Overview
Problem
Vehicle battery cooling systems face challenges in effectively managing high temperatures of battery modules, which can lead to overheating and potentially dangerous conditions, especially during thermal runaway events, where existing systems may struggle to maintain coolant flow and prevent boiling.
Innovation Solution
A vehicle battery cooling system that includes multiple battery modules, a coolant pump, adjustable flow valves, temperature sensors, and an endothermic solute container, where the system selectively increases coolant flow and releases an endothermic solute into the coolant fluid when temperatures exceed a threshold, enhancing emergency thermal runaway mitigation by reducing the risk of vapor lock and prolonging the time before a thermal runaway event.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If coolant flow is increased to cool overheated battery modules, then cooling effectiveness is improved, but system complexity increases due to need for selective flow control
Solution Approach 1:
The cooling system is segmented into multiple independent coolant flow paths, each equipped with its own adjustable flow valve. This allows selective control of coolant flow to individual battery modules based on their specific thermal conditions, enabling targeted cooling without requiring system-wide complexity increases.
Solution Approach 2:
The flow valves are made adjustable and controllable, transforming the static cooling system into a dynamic one that can adapt coolant distribution in real-time. The control module dynamically adjusts valve positions based on temperature sensor feedback, optimizing cooling effectiveness while managing system complexity through intelligent control rather than mechanical complexity.
2Temperature
If endothermic solute is released into coolant fluid, then rapid cooling effect is improved, but loss of substance increases due to solute consumption
Solution Approach 1:
The endothermic solute is pre-positioned in containers within the surge tank, ready for rapid deployment when thermal runaway is detected. This preliminary preparation allows immediate cooling action without requiring continuous solute supply systems, minimizing overall solute requirements while maximizing rapid cooling effectiveness when needed.
Solution Approach 2:
The system utilizes the phase transition or dissolution process of the endothermic solute in the coolant fluid, which absorbs heat during dissolution. This chemical phase change provides rapid cooling effect, and the solute is used only in emergency situations rather than continuously, reducing total substance loss.
3Productivity
If coolant flow is restricted to non-overheated modules, then cooling efficiency is improved, but duration of action decreases due to reduced overall coolant circulation
Solution Approach 1:
The coolant circulation system is segmented into multiple parallel paths with individual flow control for each battery module. This segmentation allows the system to restrict flow to non-overheated modules while maintaining adequate circulation in other paths, preserving overall cooling duration and system productivity simultaneously.
Solution Approach 2:
Different flow rates are applied to different battery modules based on their local thermal conditions. Non-overheated modules receive restricted coolant flow to optimize efficiency, while overheated modules receive increased flow. This local differentiation maintains productive cooling throughout the system while extending overall duration of action.
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 targets overheated battery modules with increased coolant flow and the release of an endothermic solute, reducing the risk of coolant boiling and extending the time before a thermal runaway event, thereby improving heat absorption and preventing damage or fire.
Implementation Method 1
an endothermic solute container configured to release an endothermic solute into the coolant fluid
Implementation Method 2
a coolant pump configured to supply coolant fluid to each of the multiple battery modules to cool the multiple battery modules
Data Source
AI summary
A vehicle battery cooling system includes a coolant pump configured to supply coolant fluid to multiple battery modules, multiple adjustable flow valves each configured to selectively control a rate of coolant fluid flowing to a corresponding one of the multiple battery modules, multiple temperature sensors each configured to measure a temperature of one of the multiple battery modules, and a battery thermal control module. The battery thermal control module is configured to obtain a temperature of each of the multiple battery modules, determine whether one or more of the multiple battery modules has a temperature above a specified overheating threshold value, and change a setting of one or more of the multiple adjustable flow valves to allow a greater flow of coolant fluid to the at least one battery module exceeding the specified overheating threshold value as compared to other ones of the multiple battery modules.