Cell Pack Manifold Channels for Even Thermal Fluid Distribution
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Solution Overview
Problem
Existing cell pack thermal management systems face challenges in efficiently managing heat dissipation in densely packed cell matrices, leading to temperature deviations from the optimal operating range, and requiring additional weight and cost for thermal management components.
Innovation Solution
A cell pack thermal management device comprising flexible conduits, an intake manifold, and an exhaust manifold, with a series of channels in the manifold body tuned for even flow distribution, ensuring efficient heating or cooling of cells while minimizing weight and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If cells are densely packed to increase energy/power density, then energy density is improved, but heat dissipation capability deteriorates
Solution Approach 1:
The cell pack is divided into multiple zones with individual thermal management conduits for each zone, allowing localized heat dissipation control that addresses heat accumulation in densely packed cells
Solution Approach 2:
Thermal management conduits act as intermediary elements between densely packed cells and the external environment, providing dedicated heat transfer pathways that enable effective heat dissipation without increasing cell pack volume
2Temperature
If thermal management system is added to control cell temperature, then temperature control is improved, but system weight increases
Solution Approach 1:
The thermal management conduits serve multiple functions: heat dissipation during operation, heating during cold conditions, and air bubble removal during filling, eliminating the need for separate systems for each function and reducing overall weight
Solution Approach 2:
The system uses the thermal management fluid itself to perform multiple tasks including heat transfer, heating, and air bubble removal through the tuned channels, reducing the need for additional heavy components
3Temperature
If thermal management fluid is filled in system, then thermal management capability is improved, but air bubbles remain causing flow distribution issues
Solution Approach 1:
The system is designed with tuned channels that facilitate air bubble removal during the filling process before thermal operation begins, ensuring proper flow distribution is established in advance
Solution Approach 2:
The tuned channels convert the harmful effect of air bubbles into a beneficial self-cleaning mechanism by creating flow conditions that automatically remove air bubbles during system operation
4Ease of manufacture
If conventional manifold channels are used, then manufacturing is simplified, but flow distribution uniformity deteriorates
Solution Approach 1:
Different sections of the manifold channels have different geometries (tuned channels) optimized for specific flow distribution requirements, allowing non-uniform channel design that achieves uniform flow distribution while remaining manufacturable
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 solution provides efficient thermal management by ensuring even distribution of thermal fluid, reducing pressure drop, and optimizing flow rates, thereby maintaining cell pack performance within the optimal temperature range while minimizing system weight and cost.
Implementation Method 1
During use the fluid is pumped around the system to either heat or cool the cell pack
Implementation Method 2
Before use, the system is filled with a thermal management fluid, for example a mix of water and ethylene glycol
Implementation Method 3
During use the fluid is pumped around the system to either heat or cool the cell pack
Implementation Method 4
a series of channels tuned for even flow distribution
Data Source
AI summary
A cell pack thermal management device suitable for use with a cell pack. The device has a plurality of flexible conduits, an intake manifold and an exhaust manifold. The plurality of flexible conduits are fluidly connectable between the intake manifold and the exhaust manifold to provide a plurality of fluid paths between the intake manifold and the exhaust manifold. At least one of the intake manifold and the exhaust manifold has a manifold body, a plurality of conduit ports adapted to fluidly mate with an inlet or the outlet port of each respective flexible conduit, and a system port. The plurality of conduits ports and the system port are fluidly connected within the manifold body by a series of channels tuned for even flow distribution.