Battery Cross-Member Cooling Paths for Thermal Reliability
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Solution Overview
Problem
Existing battery heat dissipation systems are inefficient, leading to a heightened risk of thermal malfunction in electric and hybrid vehicles.
Innovation Solution
A battery cooling and reinforcement system with crossbeams and connectors that form conduits for refrigerant fluid circulation, allowing efficient heat transfer and dissipation through a refrigerant, enhancing thermal management and mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional cooling plate is used for heat dissipation, then the battery structure is simple, but the heat dissipation efficiency is insufficient leading to thermal malfunction risk
Solution Approach 1:
The cooling system is segmented into multiple cross-members with internal conduits distributed throughout the battery structure, allowing heat to be dissipated at multiple locations simultaneously rather than through a single cooling plate, thereby improving thermal management reliability while distributing system complexity
Solution Approach 2:
The cooling function is merged with the structural reinforcement function by integrating refrigerant conduits into the cross-members that also provide mechanical support to the battery modules, achieving dual functionality and improving reliability without proportionally increasing complexity
2Loss of energy
If cross-members with internal conduits are added to improve cooling efficiency, then heat dissipation efficiency is improved, but the device complexity increases
Solution Approach 1:
The cross-members serve multiple functions: they provide structural reinforcement to the battery housing and simultaneously act as heat dissipation conduits for the refrigerant, eliminating the need for separate cooling components and reducing overall system complexity while improving heat dissipation efficiency
Solution Approach 2:
The refrigerant conduits are nested within the cross-members, with the cooling function embedded inside the structural elements, allowing the cooling system to utilize existing structural space and reducing the need for additional external cooling components
3Strength
If multiple cross-members are added to enhance structural reinforcement, then mechanical strength is improved, but the device complexity and refrigerant path complexity increase
Solution Approach 1:
The battery structure is divided into multiple segments with cross-members positioned at regular intervals to provide localized reinforcement, and the refrigerant cooling path is similarly segmented through each cross-member, allowing both structural and thermal functions to be distributed and simplified
Solution Approach 2:
The cross-members are positioned asymmetrically based on thermal and structural requirements, with higher density in regions requiring both reinforcement and cooling, optimizing the balance between strength and complexity
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 reduces the risk of thermal malfunction by efficiently dissipating heat and reinforcing the battery structure, while maintaining mechanical integrity.
Implementation Method 1
the heat released being intended to pass through the cross members by thermal transfer, then into the refrigerant (28) to be evacuated
Implementation Method 2
a plurality of connectors adapted to fluidly connect the internal conduit of one of the crossbeams to the internal conduit of another of the crossbeams, the connectors and the cross members forming one or more suitable path(s) to allow the refrigerant to pass through the internal conduits
Data Source
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AI summary
A battery (10) for an electric or hybrid vehicle, comprising a casing (12) defining a housing extending in a longitudinal direction (X) and in a transverse direction (Y), a plurality of modules (16) comprising several electrochemical cells (18), and a cooling and reinforcement system (20), the system comprising: - cross members (24A, ...24F) extending transversely within the housing, and defining, respectively in the transverse direction, internal channels for receiving a refrigerant (28), each module extending longitudinally between two of the cross members and being in thermal contact with at least one of the two cross members, - connectors (30) for fluidically connecting the internal channel of one of the cross members to that of another. The connectors and the cross members form one or more paths (F1...F13) to allow the refrigerant to flow through the internal channels.