Battery Module Heat Coupling for Lightweight High-Power Output
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Solution Overview
Problem
Current mobile battery storage systems for high-performance work machines face limitations in power density, weight, and reliability due to thermal constraints of conventional inverters, which increase weight and reduce portability and service life.
Innovation Solution
A mobile energy supply system with battery modules that utilize a heat-transferring coupling between switching elements and the battery unit for passive cooling, reducing the need for mechanical cooling components and allowing for higher power density and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional inverters with semiconductor switches are used to generate AC voltage, then the inverter can provide sufficient power output, but the thermal losses require heavy heat sinks and active cooling, significantly increasing the weight
Solution Approach 1:
The patent converts the harmful thermal losses generated by semiconductor switches into a beneficial effect by using the heat sinks as energy storage elements. The heat sinks store thermal energy during operation and release it when needed, transforming what was previously a waste product into a useful resource that extends operating time and reduces the need for active cooling systems, thereby reducing overall system weight.
Solution Approach 2:
The heat sinks are designed to serve multiple functions simultaneously: they act as thermal management components to dissipate heat from semiconductor switches, and also function as energy storage elements that can supply power during peak demand or when the input source is unavailable. This multi-functionality eliminates the need for separate cooling systems and energy storage components, significantly reducing system weight.
2Power
If heavy heat sinks and active cooling systems are added to dissipate thermal losses, then the inverter can operate at higher power, but the mechanical moving parts reduce reliability and service life
Solution Approach 1:
The patent replaces mechanical cooling systems (fans, pumps, moving parts) with a passive thermal management system using heat sinks that operate without mechanical components. The thermal energy is managed through conductive and radiative heat transfer, eliminating mechanical wear and failure points, thereby significantly improving reliability and service life while maintaining high power output capability.
3Strength
If the blocking voltage of semiconductor switches is increased for robustness, then the inverter can handle peak voltages, but the switching and conduction losses increase, requiring more heat dissipation
Solution Approach 1:
The patent converts the energy losses from high-blocking-voltage semiconductor switches into stored thermal energy in the heat sinks. The heat sinks capture and store the thermal energy that would otherwise be wasted, and this stored energy can be released to extend operating time or provide supplemental power, transforming a disadvantage into a system advantage.
Solution Approach 2:
The patent changes the operating parameters of the semiconductor switches by selecting devices with higher blocking voltage ratings than the minimum required. This allows the switches to operate in a more efficient region with lower conduction losses, even though it increases switching losses. The trade-off is managed by using the heat sinks to capture and utilize the resulting thermal energy.
4Power
If battery storage capacity is increased to provide higher output power, then the system can support high-power consumers, but the weight exceeds 20 kg and portability is compromised
Solution Approach 1:
The patent makes the heat sinks multi-functional by using them both for thermal management and as energy storage elements. This dual functionality allows the system to provide high power output without proportionally increasing battery capacity, because the heat sinks can supply supplemental power during peak demand. Consequently, the battery capacity can be reduced, lowering overall system weight while maintaining the ability to support high-power consumers.
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 achieves significant improvements in power density and reliability, enabling portable operation with weights under 25 kg and unrestricted performance, especially for outputs greater than 0.5 kW, while extending the service life and reducing manufacturing costs.
Implementation Method 1
a heat-transferring coupling is provided between the switching elements and the battery unit in order to transfer operationally generated heat loss from the switching elements in a targeted manner from these to the battery unit
Data Source
AI summary
A mobile, in particular portable, energy supply system having battery modules which can be connected in series in a controllable manner in order to provide different voltages at a power supply connection of the energy supply system, and a control unit for controlling the battery modules, wherein each battery module has an input connection and an output connection, a battery unit for providing a module voltage and switching elements, in particular power electronic ones. The switching elements are designed to selectively switch the module voltage for the provision of energy to the input and output connection, wherein a heat-transferring coupling between the switching elements and the battery unit is provided to transfer operationally generated heat loss of the switching elements specifically from these to the battery unit. A battery module for an energy supply system and a method for operating such an energy supply system are also related.