Battery Heat Exchanger With Conductive Isolation Layer
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Solution Overview
Problem
Existing heat exchangers for thermally controlled battery systems are expensive, require significant installation space, and are inefficient in energy management, complicating manufacturing and assembly.
Innovation Solution
A heat exchanger with a thermally conductive fluid channel and an electrically isolating, thermally conductive compensation layer, incorporating a heating element, is designed to efficiently manage battery temperature by guiding a coolant fluid through the channel, using thermally conductive materials to enhance heat transfer for both cooling and heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional heat exchangers are used for battery thermal management, then temperature control function is provided, but device complexity and installation space increase
Solution Approach 1:
The patent combines the cooling function (fluid channel) and heating function (heating element with thermally conductive compensation layer) into a single integrated heat exchanger unit. This merging eliminates the need for separate cooling and heating systems, reducing device complexity and installation space while maintaining both temperature control functions.
Solution Approach 2:
The heat exchanger is designed as a multi-functional component that can perform both cooling (through the fluid channel) and heating (through the heating element and compensation layer) operations. This universal design allows a single device to replace multiple specialized components, simplifying the overall thermal management system.
2Reliability
If conventional heat exchangers are used for battery thermal management, then temperature control function is provided, but manufacturing and assembly costs increase
Solution Approach 1:
By integrating the heating element and thermally conductive compensation layer directly into the heat exchanger structure, the patent reduces the number of separate components that need to be manufactured and assembled. This integration simplifies the manufacturing process and assembly operations, thereby reducing costs.
Solution Approach 2:
The use of thermally conductive compensation layer material that is both electrically insulating and thermally conductive creates a composite structure that combines multiple functions in a single material layer. This composite approach reduces the need for additional components and simplifies manufacturing.
3Loss of energy
If thermally conductive material is used in fluid channel, then heat transfer efficiency is improved, but electrical insulation requirement complicates design
Solution Approach 1:
The patent employs a thermally conductive compensation layer material that possesses dual properties: electrical insulation and thermal conduction. This composite material simultaneously addresses the need for heat transfer efficiency (by conducting heat) and electrical insulation requirements (by blocking electrical current), eliminating the need for separate insulation components.
Solution Approach 2:
The heating element is positioned adjacent to the fluid channel wall, and the thermally conductive compensation layer is placed specifically at the interface where heating occurs. This localized arrangement ensures that thermal conduction occurs where needed (from heating element through compensation layer to fluid channel) while electrical insulation is provided only where required, optimizing both heat transfer and electrical safety.
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 proposed heat exchanger system reduces manufacturing and assembly complexity, requires less space, and improves energy efficiency, enabling effective thermal management of batteries while minimizing costs.
Implementation Method 1
at least a part of the fluid channel facing the battery comprises a thermally conductive material
Implementation Method 2
at least one heating element arranged on at least one wall of the fluid channel
Implementation Method 3
at least one electrically isolating and thermally conductive compensation layer comprising at least one soft and flexible material
Data Source
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AI summary
A heat exchanger (110) arrangeable adjacent to at least one battery (114) is proposed. The heat exchanger (110) is configured for controlling the temperature of the battery (113) and comprises at least one fluid channel (118) for guiding a coolant fluid (120) through the heat exchanger (110), wherein at least a part of the fluid channel (118) facing the battery (114) comprises a thermally conductive material. The heat exchanger (110) further comprises at least one heating element (126) arranged on at least one wall (121) of the fluid channel (118). The heat exchanger (110) further comprises at least one electrically isolating and thermally conductive compensation layer (116) comprising at least one soft and flexible material. Further proposed is a thermally controlled battery system (112).