Battery Pack Thermal Modules for Uniform Cell Heating and Cooling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current battery pack thermal management systems face challenges in efficiently managing the temperature of large battery packs, particularly in electric vehicles, due to internal heating during charge and discharge, and the need for active cooling and heating, which existing methods such as air cooling and flooded cooling are inadequate for high current applications.
Innovation Solution
The implementation of thermal control modules that thermally couple to the side wall and bottom end of each battery in a battery pack, using thermal fluids circulated through a thermal plate and engagement components to provide cooling or heating without direct contact with the batteries, ensuring uniform heat transfer and preventing electrical shorts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If thermal control modules are implemented to actively cool and heat batteries, then temperature management effectiveness is improved, but device complexity increases
Solution Approach 1:
The battery pack is divided into multiple battery groups, with each group having its own thermal control module. Each thermal control module is further segmented into a thermal plate and multiple battery engagement components, allowing independent temperature management for each battery group while maintaining overall system efficiency.
Solution Approach 2:
The thermal control module is designed as a multi-functional component that can both cool and heat batteries depending on operational needs. The thermal plate serves multiple purposes: it conducts heat away from batteries during charging, provides thermal isolation during storage, and can be integrated with heating elements for cold weather operation.
2Loss of energy
If thermal control modules thermally couple to side wall and bottom end of each battery, then heat transfer efficiency is improved, but manufacturing precision requirements increase
Solution Approach 1:
The battery engagement components are designed with non-uniform geometry, featuring a larger thermal contact area at the bottom end and a smaller contact area at the side wall. This local quality variation optimizes heat transfer at each contact point while accommodating manufacturing tolerances and battery dimensional variations.
Solution Approach 2:
The thermal control module incorporates adjustable parameters including thermal plate thickness, engagement component geometry, and thermal fluid flow rate. These parameters can be optimized during manufacturing to achieve desired heat transfer efficiency while maintaining feasibility within standard manufacturing tolerances.
3Reliability
If thermal fluid is circulated through thermal plate without direct contact with batteries, then electrical safety is improved, but thermal coupling effectiveness decreases
Solution Approach 1:
The thermal control module introduces intermediate components (thermal plate and battery engagement components) that serve as thermal mediators between the batteries and the circulating thermal fluid. These intermediaries maintain electrical isolation while providing efficient thermal coupling through their thermally conductive materials and optimized contact surfaces.
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 manages the temperature of battery packs, preventing overheating during rapid charging and discharging, and maintaining optimal operating ranges, thereby enhancing the performance and safety of lithium-ion batteries and other types of batteries in various applications.
Implementation Method 1
Thermal fluid is circulated through at least the thermal plate to provide cooling or heating to the batteries without any direct contact between the thermal fluid and the batteries
Data Source
AI summary
Provided are methods and systems for battery pack thermal management, such as heating and cooling of individual batteries arranged into battery packs. The methods and systems use thermal control modules, specifically configured to thermally couple to the side wall and the bottom end of each battery in a battery pack. In some examples, a thermal control module comprises a thermal plate and one or two battery engagement components, connected and thermally coupled to the thermal plate. Each battery engagement component comprises a plurality of battery receiving openings. When the batteries are installed into these openings, the side wall and the bottom end of each battery are thermally coupled to the thermal control module. Thermal fluid is circulated through at least the thermal plate to provide cooling or heating to the batteries without any direct contact between the thermal fluid and the batteries.