Battery Thermal Management Using Dual Phase-Change Materials
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Solution Overview
Problem
Existing thermal management systems for DC power sources, such as lithium-ion batteries, increase vehicle weight, noise, and vibration while consuming energy, and fail to efficiently maintain optimal temperature ranges, leading to reduced battery service life and vehicle performance.
Innovation Solution
A thermal management system utilizing phase-change materials with different phase-change temperatures integrated into a battery mounting bracket and vehicle body structural element, creating conductive heat transfer paths to manage battery temperature, including a first thermal element attached to the battery end and a second thermal element attached to the battery's sides, top, or bottom, with a heat sink for efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional thermal management systems (coolant circulation, fan) are used to manage battery temperature, then battery temperature control is achieved, but vehicle weight increases, noise and vibration increase, and energy consumption increases
Solution Approach 1:
The patent combines the thermal management function with the existing battery mounting bracket structure. The heat transfer paths are integrated into the mounting bracket that already exists for securing the battery, eliminating the need for separate cooling components and reducing overall vehicle weight.
Solution Approach 2:
The system utilizes the vehicle body structure itself as the heat sink, allowing the battery to dissipate heat through conductive paths to the vehicle body. This self-service approach eliminates the need for external cooling systems, reducing weight, noise, and energy consumption.
2Temperature
If conventional thermal management systems (coolant circulation, fan) are used to manage battery temperature, then battery temperature control is achieved, but device complexity increases
Solution Approach 1:
The thermal management function is merged with the battery mounting bracket and vehicle body structure, eliminating the need for separate cooling systems, coolant circuits, and control mechanisms. This integration significantly reduces device complexity while maintaining effective temperature control.
Solution Approach 2:
The patent extracts the thermal management function from complex mechanical cooling systems and implements it through simple conductive heat transfer paths using existing structural components, thereby reducing system complexity.
3Temperature
If conventional thermal management systems (coolant circulation, fan) are used to manage battery temperature, then battery temperature control is achieved, but energy consumption increases
Solution Approach 1:
The battery management system uses the vehicle body structure as a passive heat sink, requiring no active cooling components. Heat is dissipated automatically through conductive paths without consuming electrical energy, eliminating the need for pumps, fans, or control systems.
Solution Approach 2:
The patent replaces active mechanical cooling systems (pumps, fans) with passive thermal conduction through structural components, eliminating energy consumption associated with operating mechanical cooling devices.
4Temperature
If battery power derating is applied to control heat generation, then battery temperature is reduced, but vehicle performance decreases
Solution Approach 1:
The patent introduces thermal interface materials and heat transfer paths as intermediaries between the battery and vehicle body structure. These intermediaries efficiently conduct heat away from the battery, allowing full power operation without thermal derating by providing an effective heat dissipation pathway.
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 system effectively maintains battery temperature within the optimal range, reducing derating and enhancing vehicle performance by minimizing weight, noise, and energy consumption, while extending battery service life.
Implementation Method 1
The first thermal element is composed from a first phase-change material having a first phase-change temperature
Implementation Method 2
the second thermal element is composed from a second phase-change material having a second phase-change temperature
Implementation Method 3
a first conductive heat transfer path being defined between the battery, the first thermal element, the battery mounting bracket and the vehicle body structural element
Data Source
AI summary
A thermal management system for an on-vehicle battery includes a battery, a first thermal element, a second thermal element, a battery mounting bracket, and a vehicle body structural element. The battery mounting bracket includes a first portion attached to the vehicle body structural element, and a second portion attached to the first thermal element. The first thermal element is attached to the first end portion of the battery, and the second thermal element is attached to at least one of the second end portion, the first and second side portions, the top portion or the bottom portion of the battery. The first thermal element is composed from a first phase-change material having a first phase-change temperature and the second thermal element is composed from a second phase-change material having a second phase-change temperature, wherein the first phase-change temperature is greater than the second phase-change temperature.