Battery Pack Thermal Coupling Assessment Using Voltage Response
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Solution Overview
Problem
Assessing the performance of thermal management systems in electric vehicles without disassembling the battery pack or using costly and time-consuming methods like CT scans is challenging, as existing methods fail to efficiently evaluate the thermal coupling between battery cells and cold plates.
Innovation Solution
A method that determines a test load for battery cells, measures voltage responses, and generates a thermal assessment based on resistivity values to evaluate the performance of the thermal management system, indicating desirable or undesirable performance based on voltage measurements and resistivity profiles, allowing for assessment without disassembly or costly investigations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If CT scans or disassembly methods are used to assess thermal management system performance, then measurement precision is improved, but loss of time and cost increase significantly
Solution Approach 1:
The patent replaces physical disassembly and CT scanning with an electrical measurement system. By applying a test load to the battery pack and measuring voltage responses, the system derives resistivity values that indicate thermal coupling quality without mechanical intervention or expensive imaging equipment.
Solution Approach 2:
The patent introduces voltage measurements and resistivity calculations as intermediary parameters to assess thermal coupling. Instead of directly observing thermal properties, the system uses electrical resistance changes as a proxy indicator of thermal management system performance.
2Measurement precision
If CT scans or disassembly methods are used to assess thermal management system performance, then measurement precision is improved, but cost increases significantly
Solution Approach 1:
The patent replaces expensive CT scanning equipment and disassembly procedures with simple voltage measurement circuitry. The test load and voltage sensing components are significantly cheaper than CT scanners, reducing assessment costs while maintaining measurement capability through electrical rather than imaging methods.
Solution Approach 2:
The patent uses inexpensive test loads and voltage measurement components that can be easily replaced or reset. The assessment methodology relies on simple electrical components rather than expensive, complex imaging equipment, enabling cost-effective repeated testing.
3Reliability
If thermal management system is integrated with battery pack, then reliability is improved, but device complexity increases making assessment difficult
Solution Approach 1:
The patent extracts the thermal coupling assessment function from the complex integrated system by isolating it as a separate electrical measurement process. By applying test loads and measuring voltage responses, the assessment methodology separates thermal evaluation from the overall system complexity, enabling independent verification of thermal management performance.
Solution Approach 2:
The patent introduces electrical resistance measurements as an intermediary that bridges the gap between the integrated thermal management system and assessable parameters. The voltage responses and derived resistivity values serve as intermediate indicators that translate complex thermal behavior into measurable electrical properties.
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
Enables efficient evaluation of thermal management system performance by correlating voltage responses with resistivity values, indicating proper thermal coupling and heat dissipation without disassembling the battery pack, thus reducing costs and time.
Implementation Method 1
determining a test load to be applied to a plurality of battery cells included as part of the battery pack
Implementation Method 2
the wet-out-state characterizing thermal coupling via a thermal interface material (TIM) between the battery cells and a cold plate
Implementation Method 3
deriving resistivity values for the battery pack according to a voltage response of the battery cells when subjected to a test load
Data Source
AI summary
A method for assessing performance of a thermal management system configured for thermally managing a battery pack of an electric vehicle. The method may include determining a voltage response of the battery pack while subjected to a test load and generating a thermal assessment for the thermal management system based on the voltage response and/or resistivity values derived therefrom.