Battery Pack Terminal Cooling With Activity-Based Flow Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery pack cooling systems are inefficient as they either fully enclose battery cells or lack targeted heat management, leading to suboptimal thermal regulation and increased volume requirements.
Innovation Solution
A cooling system that encloses only the anode and cathode terminals and busbars of battery cells within a container, utilizing a closed loop with a heat removal system and a medium that circulates to extract heat from the terminals and busbars, with a controller managing the system's operation based on vehicle activity levels to optimize heat removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If battery cells are fully enclosed for cooling, then thermal management is achieved, but cooling system volume increases
Solution Approach 1:
The cooling system is segmented to cool only specific components (terminals and busbars) rather than enclosing entire battery cells. The container encloses only the anode terminal, cathode terminal, and busbars of each battery cell, creating separate cooling zones that reduce overall cooling system volume while maintaining effective thermal management of heat-generating components.
Solution Approach 2:
The cooling approach applies local quality by targeting specific components (terminals and busbars) that generate the most heat, rather than uniformly cooling entire battery cells. The container is positioned to enclose only these critical components, and the cooling medium is directed specifically at these areas through openings in the container, optimizing thermal management efficiency.
2Loss of energy
If cooling medium is directed at terminals and busbars, then heat transfer efficiency improves, but system complexity increases
Solution Approach 1:
The cooling system uses multiple openings distributed in the container to direct cooling medium at different locations (anode terminal, cathode terminal, and busbars). This segmented approach ensures comprehensive heat transfer coverage across all critical components while maintaining a relatively simple overall system structure.
Solution Approach 2:
The container serves multiple functions: it encloses the terminals and busbars, provides structural support, and acts as a distribution manifold for the cooling medium through its openings. This multi-functionality reduces the need for separate components, thereby reducing system complexity while maintaining effective heat transfer.
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 approach effectively reduces the volume required for cooling while ensuring efficient heat transfer and thermal management, maintaining battery pack temperature across varying activity levels, thereby enhancing the performance and longevity of electric vehicle batteries.
Implementation Method 1
a medium cooled by the heat removal system and directed by the plurality of openings against the at least two busbars and the anode terminal and cathode terminal
Implementation Method 2
Medium heated by the at least two busbars and the anode terminal and cathode terminal of each battery cell may pass out of the outlet of the channel of the container to the heat removal system
Data Source
AI summary
Implementations of a method of cooling a battery pack may include including a controller coupled with a plurality of battery cells; providing a container enclosing only an anode terminal and a cathode terminal of each battery cell, the container sealed against exterior surfaces of the plurality of battery cells. The method may include monitoring an activity of an electric vehicle using the controller and when the activity of the electrical vehicle is below a first threshold, the controller does not activate a heat removal system in fluid communication with the container; when the activity of the electrical vehicle is above the first threshold but below a second threshold, the controller activates the heat removal system in a low throughput mode; and when the activity of the electrical vehicle is above the second threshold, the controller activates the heat removal system in a high throughput mode.