Temperature Regulated Battery With Segmented Cooling Channels
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Solution Overview
Problem
Existing temperature-controlled batteries for vehicle drives face challenges in achieving uniform temperature distribution and efficient heat dissipation, leading to suboptimal operating conditions and reduced service life under varying loads.
Innovation Solution
The battery design incorporates a thermally insulated housing with corrugated metal sheets between flat battery cells, compressed gas pressure pockets for even clamping, and a heat exchanger system using miniature pumps and transformer oil for enhanced heat transfer, connecting the battery cells directly to a heat exchanger space with cooling coils for efficient heat exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If battery cells are arranged in battery chambers with metallic retaining walls, then structural stability is improved, but heat dissipation efficiency deteriorates because heat can only conduct along the metallic walls to a cooled base plate
Solution Approach 1:
The battery housing is divided into multiple battery chambers (first, second, third, and fourth chambers) separated by internal partitions. Each chamber can be independently cooled, allowing segmented heat management. The base plate is also segmented with multiple cooling channels running in different directions (first and second directions), enabling distributed heat dissipation across the entire battery base rather than relying on a single cooling point.
Solution Approach 2:
The cooling system transitions from one-dimensional heat conduction along vertical metallic walls to two-dimensional heat dissipation through the base plate. Cooling channels are arranged in both first and second directions (perpendicular to each other) on the base plate, creating a grid-like heat dissipation network that covers the entire battery footprint, effectively adding a horizontal dimension to heat management.
2Loss of energy
If a gaseous cooling medium flows through the battery, then heat exchange capability is improved, but temperature distribution uniformity deteriorates under varying loads
Solution Approach 1:
The patent employs a liquid cooling medium (transformer oil) circulating through hydraulic channels formed by the corrugated sheets and battery chamber structures. This hydraulic cooling system replaces gaseous cooling, providing better heat capacity and more stable thermal management. The liquid medium flows through defined channels ensuring consistent contact with heat-generating components, improving both heat exchange capability and temperature uniformity.
Solution Approach 2:
The cooling system parameters are dynamically adjusted by changing the flow rate of the transformer oil through the cooling channels. The pump can vary the circulation speed to match different battery load conditions, ensuring optimal heat dissipation across varying operational requirements. This parameter adjustment capability maintains temperature uniformity whether the battery is under light or heavy load.
3Area of stationary object
If corrugated metal sheets are used as spacers to form coolant-receiving spaces, then heat transfer surface area is improved, but device complexity increases
Solution Approach 1:
The corrugated metal sheets serve multiple functions simultaneously: they act as spacers to maintain battery cell spacing, form coolant-receiving spaces for heat exchange, provide structural support between battery chambers, and create the cooling channels themselves. This multi-functionality reduces the need for separate dedicated cooling components, thereby increasing heat transfer surface area without proportionally increasing device complexity.
Solution Approach 2:
The corrugated sheets are made of thin metal material that can be easily formed into complex three-dimensional cooling channel structures. These thin-walled corrugated structures provide large surface area for heat transfer while remaining lightweight and easy to integrate into the battery assembly, avoiding the need for heavy or complex rigid cooling structures.
4Stress or pressure
If compressed gas pressure pockets are used to clamp battery cells evenly, then contact pressure uniformity is improved, but manufacturing complexity increases
Solution Approach 1:
The compressed gas pressure pockets are designed to automatically adjust and maintain uniform contact pressure on the battery cells. The gas pressure self-regulates to distribute force evenly across the cell surfaces, compensating for minor variations in cell dimensions or positioning. This self-adjusting mechanism eliminates the need for complex mechanical pressure distribution systems or manual adjustment procedures during assembly.
Solution Approach 2:
The compressed gas acts as an intermediary medium between the clamping structure and the battery cells. Instead of direct mechanical contact that might create pressure points or uneven forces, the gas transmits pressure uniformly through its fluid nature, ensuring even contact across the entire battery cell surface while simplifying the overall clamping mechanism design.
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 configuration ensures improved and uniform temperature distribution, allowing the battery to withstand higher loads and extend its service life by effectively managing heat dissipation and supply, maintaining optimal operating temperatures.
Implementation Method 1
a free-flowing first heat carrier that is in contact with the battery cells is enclosed, which is in heat exchange via heat transfer surfaces enclosed in the battery housing with at least one second heat carrier
Implementation Method 2
heat exchange via heat transfer surfaces enclosed in the battery housing with at least one second heat carrier enclosed in a duct system
Implementation Method 3
for forced convection on the battery cells within the battery housing at least one pump is included, the inflow and outflow in Strömu ngs connection with the first heat carrier
Implementation Method 4
corrugated metal sheets between flat battery cells... improved and uniform temperature distribution... effectively managing heat dissipation
Data Source
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AI summary
The temperature-controlled battery, which is intended in particular as an energy source of a vehicle drive, has numerous flat battery cells (17), which are electrically interconnected and which are combined parallel to each other and are distributed in several battery chambers (9-12) in a thermally insulated battery housing (3) to form cell packages (16). Spacers (18) are arranged between the battery cells. A flowable first heat-transfer medium in contact with the battery cells (17) is enclosed in the battery housing (3). The first heat-transfer medium exchanges heat with a second heat-transfer medium enclosed in a channel system (22, 23) by means of heat-transfer surfaces (22, 23) enclosed in the battery housing (3). Said channel system (22, 23) has a supply line and a discharge line leading out of the battery for the temperature-controlled exchange of heat outside the battery. For forced convection at the battery cells (17), at least one pump (21) is enclosed in the battery housing (3). Said pump has a flow connection to the first heat-transfer medium on the supply and outlet sides. The battery can be particularly highly loaded due to the thus substantially improved and uniform cooling of the battery cells (17).