Battery Thermal Management with Powder Composite and Liquid Cooling
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Solution Overview
Problem
Existing thermal management systems for Li-ion battery cells in electric vehicles struggle to maintain optimal temperature ranges, leading to thermal runaway or reduced performance due to inefficient heat dissipation, and existing phase change materials cause stress during temperature changes.
Innovation Solution
A thermal management system comprising a solid component in powder form and a liquid conveying component, with sensors and a pump, to regulate cell temperatures within a predefined range using a synergistic powder mixture of organic and inorganic compounds, and a heat exchanger.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If phase change material (PCM) is used to absorb heat during phase change, then heat dissipation efficiency is improved, but stress in all directions is generated when PCM expands due to temperature rise
Solution Approach 1:
The patent uses a porous support structure to contain the phase change material. The porous architecture allows the PCM to expand into the void spaces during phase change, accommodating volume expansion without generating excessive stress on surrounding components while maintaining thermal contact for efficient heat dissipation.
Solution Approach 2:
The patent creates a composite system combining phase change material with a support structure. This composite approach allows the PCM to provide latent heat absorption for efficient cooling while the support structure provides mechanical stability and stress distribution, resolving the contradiction between heat dissipation efficiency and stress generation.
2Productivity
If liquid cooling system with pumps and radiators is used, then heat dissipation capability is improved, but system complexity and power consumption increase
Solution Approach 1:
The patent employs passive phase change cooling where the phase change material automatically absorbs heat during phase transition without requiring external power input. The system self-regulates temperature based on thermal conditions, eliminating the need for pumps, radiators, and complex control systems while maintaining effective heat dissipation capability.
Solution Approach 2:
The patent replaces the active mechanical liquid cooling system (pumps, radiators) with a passive phase change material-based thermal management system. The phase change process naturally handles heat transfer without mechanical intervention, significantly reducing system complexity and power consumption while maintaining heat dissipation effectiveness.
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
Effectively maintains cell temperatures within optimal ranges, preventing thermal runaway and enhancing energy efficiency by minimizing power consumption, suitable for various battery configurations and extreme conditions.
Implementation Method 1
a solid component in powder form in contact with the outer surfaces of the plurality of cells and substantially filling the interstices between the plurality of cells
Implementation Method 2
a liquid conveying component configured to exchange heat with one of the solid component, the cell surface, and both
Implementation Method 3
a heat exchanger, located outside the battery, in fluid communication with the liquid conveying component for exchanging heat
Implementation Method 4
for exchanging heat, for keeping a temperature of the cells in the battery within a predefined range of temperatures
Data Source
AI summary
The present disclosure relates to a thermal management system for a battery. The system comprises a solid component and a liquid conveying component for efficient heat dissipation in a battery comprising plurality of cells enclosed in a casing. The solid component is a powder mixture comprising organic and inorganic compounds mixed in optimum ratio for exchanging heat with the plurality of cells. The liquid cooling component comprises of plurality of liquid conveying component arranged for the flowing liquid coolant to exchange heat with the solid component and conveying the heat out of the battery.