Battery Thermal Management Using State of Charge Control

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Solution Overview

Problem

Current thermal management systems are inefficient in handling transient thermal loads and often result in oversized or poorly controlled components, as they primarily focus on peak constant loads without considering the thermal mass of components.

Innovation Solution

A thermal management system that utilizes the thermal capacitance of an electrical source, such as a battery, to optimize cooling output, efficiency, design, and size, by incorporating a controller to manage cooling based on the state of charge of the electrical source and a cooling reservoir to supplement cooling capacity, especially during dynamic thermal loads.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If thermal management systems are designed to handle peak constant thermal loads without considering transient loads or thermal mass, then the system can ensure adequate cooling capacity for maximum loads, but the components become oversized and inefficient

Engineering Contradiction:

Improvecooling capacity adequacyVSAvoidcomponent size

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The system pre-cools the electrical source (battery) during periods of low thermal load to store cooling capacity in the thermal mass of the battery. This preliminary action allows the battery to absorb heat during transient high-load periods, reducing the required size of active cooling components while maintaining adequate cooling capacity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system dynamically adjusts cooling parameters based on the state of charge and thermal conditions of the electrical source. By changing operational parameters (cooling activation thresholds, cooling intensity) rather than maintaining fixed oversized capacity, the system achieves reliable cooling with smaller, more efficient components.

Inventive Principle:

Principle #35Parameter changes

2Device complexity

If thermal management systems focus only on peak constant loads, then the system design is simplified, but the system becomes inefficient in handling transient thermal loads

Engineering Contradiction:

Improvesystem design simplicityVSAvoidthermal load management efficiency

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The electrical source (battery) serves dual functions: it is both the component requiring cooling and the thermal storage medium that actively participates in thermal management. The battery's thermal mass automatically absorbs and releases heat based on its charge state, providing self-regulating thermal buffering without complex control systems.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The cooling system is designed to handle multiple types of thermal loads (constant and transient) and multiple operational states (charging, discharging, idle) through a unified control approach. The same cooling infrastructure serves both peak constant loads and transient spikes, eliminating the need for separate specialized systems.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Temperature

If the cooling system operates continuously to maintain optimal temperature, then temperature stability is improved, but energy consumption increases

Engineering Contradiction:

Improvetemperature stabilityVSAvoidcooling energy consumption

Core Design Contradiction:

TemperatureVSUse of energy by moving object

Solution Approach 1:

Instead of continuous cooling operation, the system uses periodic cooling cycles activated only when the battery state of charge and thermal conditions warrant it. The cooling system operates intermittently to maintain temperature within acceptable ranges, leveraging the battery's thermal mass to bridge periods between cooling cycles and reduce overall energy consumption.

Inventive Principle:

Principle #19Periodic action

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 manages both dynamic and steady-state thermal loads by optimizing cooling distribution and delaying cooling when the electrical source is fully charged, thereby improving the overall efficiency and reducing the size and cost of thermal management components.

Implementation Method 1

the electrical source being configured to store thermal energy and supply electricity to an electrical apparatus

Methodology Applied

Scientific EffectThermal capacitance: Thermal Energy Storage

Implementation Method 2

a cooling source; and a controller configured to: cause the electrical apparatus to be cooled with the cooling source

Methodology Applied

Scientific EffectHeat transfer: Heat Exchanger

Data Source

PatentUS10654162B2Thermal management system

Publication Date: 2020.05.19 ROLLS ROYCE NORTH AMERICAN TECHNOLOGIES INC

AI summary

Systems and methods for thermal management are provided. Thermal management components may include an electrical source and a cooling source. The electrical source may supply electricity to an electrical apparatus. In addition, the thermal management components store thermal energy. A controller may cause the electrical apparatus to be cooled by the cooling source and delay or suspend cooling the electrical source with the cooling source while a state of charge of the electrical source is greater than a predefined value for the electrical source. The state of charge of the electrical source may include a measurement of cooling capacity available by the electrical source.