Battery Thermal Management System with Modular Cooling Architecture
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Solution Overview
Problem
Advanced high energy density batteries in electric vehicles require precise temperature management to maintain optimal performance, but existing systems are inefficient and costly due to conflicting thermal demands and reliance on vehicle climate systems.
Innovation Solution
A dedicated battery thermal management system that uses a circuit with a pump, evaporator/chiller, condenser, and radiator to transfer heat, adaptable to different media, and designed for reliability and minimal maintenance, with components optimized for efficiency and located within the battery pack for reduced plumbing and control interfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a dedicated battery thermal management system is implemented, then temperature control precision is improved, but system complexity and cost increase
Solution Approach 1:
The thermal management system is segmented into distinct functional modules: a coolant circulation system with pump and radiator for passive cooling, and a separate refrigeration system with compressor, evaporator, and condenser for active cooling. This segmentation allows each subsystem to operate independently at optimal design points, improving temperature control precision while managing overall system complexity through modular architecture.
Solution Approach 2:
The system incorporates a multi-functional thermal management architecture that can operate in multiple modes: passive cooling mode using only the coolant circulation system, active cooling mode using the refrigeration system, and combined mode using both systems simultaneously. This universality allows the system to handle diverse thermal demands of high energy density batteries across different operating conditions, achieving precise temperature control without requiring separate dedicated systems for each cooling scenario.
2Reliability
If the refrigeration system is designed with minimum fittings, then reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The refrigeration system is designed as an integrated one-piece unit where the compressor, evaporator, condenser, and associated piping are merged into a single fabricated assembly with minimal fittings. This merging eliminates numerous potential leak points and failure modes associated with multiple separate components and connections, significantly improving system reliability. The integrated design reduces the number of assembly steps and potential error sources during manufacturing, thereby mitigating the increase in manufacturing complexity.
3Volume of stationary object
If the battery thermal system is located within the battery pack, then system size is reduced, but heat transfer efficiency may be compromised
Solution Approach 1:
The thermal management system is nested within the battery pack structure, with the coolant circulation channels and refrigeration components integrated into the existing battery housing and thermal management architecture. This nesting approach minimizes the overall system volume by utilizing the available space within the battery pack enclosure. The design incorporates optimized heat transfer surfaces and direct thermal coupling between the battery cells and coolant channels, ensuring that heat transfer efficiency is maintained despite the compact integrated layout.
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
The system effectively maintains battery temperatures within specified limits, reducing energy consumption and system size, while minimizing downtime and maintenance, and optimizing thermal and climate systems without compromising performance.
Implementation Method 1
using an evaporator/chiller to transfer heat from the coolant to a refrigerant
Implementation Method 2
using an evaporator/chiller to transfer heat from the coolant to a refrigerant
Implementation Method 3
using a condenser to transfer heat from the refrigerant to the coolant
Implementation Method 4
using a radiator to transfer heat from the coolant to ambient air
Implementation Method 5
using a radiator to transfer heat from the coolant to ambient air
Implementation Method 6
a pump for circulating coolant in the circuit
Data Source
AI summary
The method for thermal management of a battery can include vehicle systems to control the thermal input to the battery and a dedicated battery thermal management system. The battery thermal management system includes transferring battery heat to coolant flowing in a circuit, if ambient air temperature is greater than the battery temperature, using an evaporator/chiller to transfer heat from the coolant to a refrigerant, using a condenser to transfer heat from the refrigerant to the coolant, and using a radiator to transfer heat from the coolant to ambient air; and if coolant can be maintained in the reference temperature range without using a heat source or refrigerant, using a radiator to transfer heat from the coolant to the ambient air.