Battery Thermal Circuits With Equal-Length Parallel Couplings
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Solution Overview
Problem
Existing temperature-control systems for batteries in vehicles face issues such as uneven performance, damage from condensation and pressure differentials, difficulty in maintaining thermal contact, and inefficient maintenance, leading to nonuniform wear and potential irreversible damage.
Innovation Solution
A temperature-control system with parallel, independent couplings for each battery unit, utilizing a heat exchange system to provide uniform temperature control, with separate inlet and outlet connectors, and a control logic to adjust flow rates based on operating conditions, ensuring equal temperature management across all units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a temperature-control system is implemented for battery modules, then temperature management is improved, but device complexity increases
Solution Approach 1:
The temperature-control system is divided into independent temperature-control elements, each serving a specific battery unit. Each element has its own inlet and outlet connectors, allowing modular installation and maintenance without affecting other units. This segmentation reduces overall system complexity while maintaining effective temperature management across multiple battery modules.
2Power
If batteries are operated at higher temperatures to increase reaction rate, then power output is improved, but battery lifespan deteriorates
Solution Approach 1:
The system dynamically adjusts the temperature-control parameters (flow rate, temperature setpoint) based on operating conditions to optimize the balance between power output and lifespan. During high-power demands, the system allows higher operating temperatures to maximize power delivery, then actively cools the batteries afterward to prevent cumulative thermal damage, thereby extending overall battery lifespan while maintaining peak performance capability.
3Manufacturing precision
If parallel independent couplings are used for each battery unit, then uniform temperature control is improved, but manufacturing complexity increases
Solution Approach 1:
The system uses segmented temperature-control elements with standardized inlet and outlet connectors for each battery unit. Each element is designed as an independent module that can be manufactured separately and then assembled into the complete system. This modular approach achieves uniform temperature distribution across all battery units while simplifying the manufacturing process through standardization and modular assembly.
4Reliability
If the entire system is drained for maintenance of an individual module, then system reliability is maintained, but maintenance efficiency deteriorates
Solution Approach 1:
The temperature-control system is segmented into independent elements, each with dedicated inlet and outlet connectors. This segmentation allows maintenance personnel to access and service individual temperature-control elements or battery units without draining the entire system. The independent coupling design enables isolated maintenance operations, significantly improving maintenance efficiency while preserving system reliability through selective servicing.
5Temperature
If thermal contact is maintained with battery modules during vehicle operation, then temperature control is improved, but thermal contact maintenance becomes difficult
Solution Approach 1:
The temperature-control elements are designed with flexible mounting mechanisms and compliant thermal interfaces that can dynamically adapt to battery module positions and vibrations during vehicle operation. The system incorporates adjustable mounting features and flexible thermal coupling materials that maintain effective thermal contact despite mechanical movements, shocks, and vibrations, thereby preserving temperature control effectiveness without requiring rigid fixed installations.
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 ensures uniform temperature control and maintenance, reducing wear and damage, while allowing independent servicing of individual units, thus enhancing the longevity and performance of the battery system.
Implementation Method 1
The temperature-control elements may be configured such that a combined length of the inlet connector and the outlet connector of each temperature-control element is substantially equal. The inlet connector and the outlet connector of each temperature-control element may be configured to couple the temperature-control element to a heat exchange system independently of other temperature-control elements of the plurality of temperature-control elements.
Data Source
AI summary
A temperature-control (TC) system comprises a plurality of TC elements. Each TC element is attached to a respective energy storage (ES) unit. Each ES unit is part of an ES module of a materials-handling vehicle. The TC elements may be coupled to a heat exchange system in parallel via separate, independent couplings. The TC elements may be further configured such that a combined length of the coupling of each TC element is substantially equal, which may result in the ES units receiving substantially equivalent TC services, even under high-load conditions.