Battery Pack Cooling Interface With External Quick-Disconnect Fittings
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Solution Overview
Problem
Existing electric vehicle charging systems face challenges in efficiently managing the temperature of battery packs during fast charging, which can lead to increased charging times and potential battery degradation.
Innovation Solution
A battery pack system that integrates a cooling circuit with an external cooling device and an internal cooling device, utilizing high-pressure quick disconnect leakless fittings and module activation valves to selectively connect with either the external or internal cooling systems based on availability, allowing for optimized coolant flow rates based on temperature and state of charge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If fast DC charging is used to charge the battery pack, then charging time is reduced, but battery temperature increases leading to potential degradation
Solution Approach 1:
The cooling circuit is pre-configured within the battery pack and can be activated before or during charging. The isolating devices are pre-positioned to enable rapid switching between cooling modes, allowing the system to proactively manage temperature rather than reactively responding to overheating
Solution Approach 2:
A coolant fluid acts as an intermediary substance to transfer heat from the battery pack to the external cooling device. The cooling circuit serves as an intermediary thermal management system that decouples the charging process from direct thermal contact, enabling fast charging while maintaining safe operating temperatures
2Reliability
If the cooling circuit is connected to the external cooling device, then cooling efficiency is improved, but system complexity increases due to additional connection components
Solution Approach 1:
The charging port and cooling interface are merged into a single integrated assembly. This integration allows the cooling circuit to share the same physical connection point as the charging port, reducing the number of separate components and connection points while maintaining the ability to connect to external cooling devices when needed
Solution Approach 2:
The cooling interface is designed with multi-functionality, serving both as a connection point for external cooling devices during fast charging and as part of the integrated charging port assembly. The isolating devices provide universal connectivity options, allowing the system to adapt to different operating conditions without requiring separate dedicated connections
3Adaptability or versatility
If the cooling circuit is isolated from the internal cooling device, then external cooling can be utilized, but the system loses the ability to use onboard cooling resources
Solution Approach 1:
The isolating devices are designed to be dynamically controllable, allowing the system to switch between connected and isolated states based on operational requirements. This dynamic capability enables the system to adapt to different charging and cooling scenarios, such as using external cooling during fast charging while maintaining the option to use internal cooling during normal operation
Solution Approach 2:
The cooling system is segmented into distinct controllable sections through the isolating devices. This segmentation allows independent control of the internal and external cooling circuit connections, enabling selective activation of cooling sources without affecting the entire system. Each isolating device can be independently operated to achieve the desired cooling configuration
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 solution enables efficient cooling and charging of battery packs during fast DC charging, reducing charging time and minimizing battery degradation by dynamically managing coolant flow and cooling sources, thereby enhancing overall system performance and longevity.
Implementation Method 1
a cooling circuit configured to cool the battery pack in a vehicle
Implementation Method 2
circulating coolant in a cooling circuit in the battery pack using the external cooling device
Implementation Method 3
a condenser that condenses the external refrigerant and releases the heat
Implementation Method 4
a chiller (heat exchanger) that exchanges heat between the external refrigerant and the internal refrigerant
Data Source
AI summary
Aspects of the disclosure provide a battery pack and a method for charging the battery pack externally. The battery pack can include a charging port configured to charge the battery pack, a cooling circuit configured to cool the battery pack in a vehicle, and a cooling interface configured to connect the cooling circuit with an external cooling device that is external to the vehicle. The charging port and the cooling interface can be integrated into a charging port assembly, the cooling interface has an inlet port and an outlet port that have high pressure quick disconnect leakless fittings, and the battery pack is configured to be charged externally via the charging port. The battery pack can include a plurality of isolating devices configured to determine whether the cooling circuit is connected to the external cooling device.