Battery Thermal Insert with Flow Channels
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Solution Overview
Problem
Current battery thermal management methods, such as air cooling, are inefficient and costly, and fail to maintain tight temperature control, leading to risks of thermal runaway and non-compliance with IEC and Telcordia standards, especially in VRLA batteries.
Innovation Solution
A battery thermal arrangement featuring thermal inserts with channels for a flowing thermal medium, connected to a circulation device, which allows for direct heat exchange with battery blocks, enabling efficient cooling and heating within optimal temperature ranges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If bulk air cooling is used, then the cooling system is simple to implement, but temperature control precision deteriorates due to low heat transfer properties of air and small gaps between battery blocks
Solution Approach 1:
The patent divides the cooling system into modular thermal inserts that can be individually placed between battery blocks. Each insert contains internal channels for thermal medium flow, creating segmented cooling zones that improve temperature control precision while maintaining system simplicity through standardized modular components.
Solution Approach 2:
The patent introduces a thermal medium (liquid or gas) as an intermediary between the cooling system and battery blocks. This thermal medium flows through channels in the thermal inserts, providing superior heat transfer compared to bulk air cooling, while the inserts themselves act as intermediaries that distribute the thermal medium efficiently across multiple battery blocks.
2Power
If active compressor cooling is used, then cooling capacity is high, but system cost increases and environmental concerns arise from refrigerant leakage
Solution Approach 1:
The patent employs hydraulic cooling by circulating liquid thermal medium through channels in the thermal inserts. This hydraulic approach provides high cooling capacity similar to compressor systems but eliminates the need for complex compression mechanisms and harmful refrigerants, reducing both system cost and environmental impact.
Solution Approach 2:
The patent extracts the compression function from the cooling system entirely, using only circulation pumps to move the thermal medium. By removing the compressor component and its associated refrigerant handling systems, the patent achieves high cooling capacity without the high costs and environmental risks of active compressor cooling.
3Volume of moving object
If Peltier coolers are used, then compact cooling is achieved, but the system cannot manage medium to high heat demands
Solution Approach 1:
The patent merges multiple cooling functions into a single thermal insert system that can be scaled. By combining circulation capability, heat exchange channels, and thermal medium storage within the insert structure, the system achieves compact form factor while maintaining the ability to handle medium to high heat demands through increased medium flow rate and extended circulation loops.
Solution Approach 2:
The patent changes the thermal medium flow parameters (flow rate, velocity, distribution) to adapt to different heat demand levels. The circulation pump can adjust flow rates, and the channel geometry can be optimized, allowing the same compact thermal insert structure to manage varying levels of heat generation from low to high demand conditions.
4Reliability
If more ventilation is provided to meet IEC and Telcordia standards, then safety is improved, but power consumption for heating and cooling increases due to heat loss
Solution Approach 1:
The patent implements thermal feedback control where temperature sensors monitor battery block temperatures and the circulation pump adjusts thermal medium flow rates accordingly. This feedback mechanism allows the system to maintain safety compliance by responding to actual thermal conditions, reducing unnecessary ventilation and associated energy consumption while meeting IEC and Telcordia standards.
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 effectively prolongs battery life, reduces the risk of thermal runaway, and meets regulatory standards by providing uniform and efficient temperature control, allowing for shorter charging times and safer operation.
Implementation Method 1
the thermal insert being in physical contact with at least a part of a side of the first battery block when filled with the thermal medium
Implementation Method 2
the thermal insert comprises an inlet and an outlet connectable to a circulation device for pumping the thermal medium through the thermal insert
Data Source
AI summary
A battery and battery thermal arrangement are provided. The battery comprises one or more battery blocks and a thermal insert configured adjacent to a first battery block or between two battery blocks, including the first battery block and a second battery block, the thermal insert comprising a channel for allowing a thermal medium flowing through the thermal insert, the thermal insert being in physical contact with at least a part of a side of the first battery block when filled with the thermal medium, the thermal insert further comprising an inlet and an outlet connectable to a circulation device for pumping the thermal medium through the thermal insert.