EV Battery Thermal Manifold Layout for Multi-Pack Coolant Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Mass-transit electric vehicles require efficient thermal management systems to minimize redundant components and weight, which is crucial for increasing driving distance and duration, while maintaining optimal battery performance.
Innovation Solution
A thermal management unit comprising a thermal base plate and manifolds that route and manage coolant flow efficiently within the vehicle, incorporating coolant convergence and divergence devices, chillers, and PTC heaters to regulate coolant temperature for optimal battery performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple battery packs are deployed in mass-transit electric vehicles, then the vehicle can provide adequate power and capacity, but the thermal management system becomes more complex and heavier due to redundant components
Solution Approach 1:
The patent combines multiple thermal management functions (cooling, heating, temperature regulation) into a single integrated thermal management unit that serves multiple battery packs. The unit features a unified coolant circulation system with manifolds that distribute coolant to multiple battery packs simultaneously, eliminating the need for separate thermal management systems for each battery pack and reducing overall system complexity and weight
Solution Approach 2:
The thermal management unit is designed as a universal system that can simultaneously perform cooling, heating, and temperature regulation functions for multiple battery packs. The single unit incorporates chillers, PTC heaters, and variable speed pumps that can serve the entire battery array, making the system multi-functional rather than requiring dedicated systems for each battery pack
2Reliability
If redundant thermal management components are included to ensure adequate cooling, then battery thermal protection is improved, but vehicle weight increases which reduces driving distance and duration
Solution Approach 1:
The patent merges multiple thermal management components into a single integrated unit with shared coolant circulation infrastructure. The unified design includes common manifolds, a single variable speed pump, and shared chillers/PTC heaters that serve multiple battery packs, significantly reducing the total weight compared to having separate thermal management systems for each battery pack while maintaining adequate thermal protection
Solution Approach 2:
The system employs variable speed pumps that can adjust their operation based on thermal demand, allowing the thermal management system to operate efficiently across different loading and environmental conditions. This parameter adjustment capability ensures reliable thermal protection while minimizing energy consumption and system weight
3Measurement precision
If separate thermal management systems are used for each battery pack, then thermal control precision is maintained, but the number of hoses and tubing increases unnecessarily
Solution Approach 1:
The patent integrates multiple battery pack thermal management into a single unified system with shared coolant circulation pathways. The design features manifolds with multiple ports that can distribute coolant to several battery packs simultaneously, reducing the total number of hoses and tubing required compared to having completely separate systems for each battery pack while maintaining thermal control precision through the shared circulation architecture
Solution Approach 2:
The manifold design incorporates segmented coolant distribution pathways with individual ports for each battery pack, allowing precise thermal control for each pack while using a single integrated pump and chiller system. This segmentation at the distribution level maintains thermal control precision without requiring separate complete systems for each battery pack
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 enhances thermal management efficiency, reducing unnecessary components and weight, thereby increasing the driving range and duration of electric vehicles by maintaining battery packs within a selected temperature range.
Implementation Method 1
connection areas for a chiller and a heater for attachment to the thermal plate
Implementation Method 2
connection areas for a chiller and a heater for attachment to the thermal plate
Data Source
AI summary
Embodiments of the invention are directed to a thermal management unit implemented within an electric vehicle including a plurality of battery packs. The thermal management unit features a first manifold operating as a coolant convergence device and a second manifold operating as a coolant divergence device. Alternatively, the thermal management unit may include a base plate, which is adapted to maintain a coolant convergence devices and a coolant divergence device.