Charged Wire Test for Heat Transfer Fluid Safety
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Solution Overview
Problem
Existing heat transfer fluids in electric vehicle battery systems pose a risk of fire and thermal runaway due to leaks, and current testing methods are inadequate for evaluating their safety and efficacy.
Innovation Solution
A charged wire test (CWT) method and system are developed to assess heat transfer fluids by measuring discharge current and temperature profiles, determining pass/fail status, and ranking fluids based on these parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heat transfer fluid is used in battery cooling systems, then thermal management efficiency is improved, but fire and thermal runaway risk increases
Solution Approach 1:
The patent applies parameter changes by systematically varying the chemical composition parameters of heat transfer fluids (different glycol types, concentrations, and additive packages) to achieve optimal balance between thermal management performance and fire safety. The CWT methodology enables identification of fluid formulations with reduced flammability while maintaining cooling efficacy.
Solution Approach 2:
The patent converts the harmful effect of heat transfer fluid leaks into a beneficial testing opportunity by using the Charged Wire Test to simulate leak scenarios and identify fluids that resist fire propagation. This transforms the risk associated with fluid leakage into a controlled evaluation method that selects safer fluid formulations.
2Device complexity
If traditional cooling solutions are used, then system simplicity is maintained, but fire safety performance deteriorates
Solution Approach 1:
The patent applies self-service by enabling the heat transfer fluid itself to provide fire safety functionality without requiring additional active cooling components or complex safety systems. By selecting fluids with inherent fire-resistant properties through proper formulation, the system maintains simplicity while improving safety performance.
3Object-affected harmful factors
If comprehensive safety testing is implemented, then fire risk reduction is improved, but testing complexity increases
Solution Approach 1:
The patent extracts the essential fire safety evaluation from complex real-world battery thermal runaway scenarios and isolates it into a controlled Charged Wire Test methodology. This extraction captures the critical fire risk assessment capability while eliminating unnecessary testing complexity by focusing on the fundamental electrochemical fire hazard mechanism.
Solution Approach 2:
The patent applies universality by designing the CWT methodology to evaluate multiple heat transfer fluid formulations and compositions using a single standardized test procedure. This multi-functional approach allows comprehensive safety assessment across different fluid types (glycol-based, water-based, synthetic) without requiring separate testing protocols for each, thereby reducing overall testing complexity.
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 CWT effectively simulates a controlled environment to evaluate the safety and conductive properties of heat transfer fluids, reducing the risk of fire and thermal runaway in electric vehicle battery systems.
Implementation Method 1
measuring temperature of the heat transfer fluid during the CWT
Implementation Method 2
measuring temperature of the heat transfer fluid during the CWT
Implementation Method 3
measuring discharge current through a test circuit formed when a cathode and an anode are at least partially immersed in the heat transfer fluid
Implementation Method 4
measuring discharge current through a test circuit formed when a cathode and an anode are at least partially immersed in the heat transfer fluid
Data Source
AI summary
A method for testing a heat transfer fluid based on a charged wire test (CWT) includes applying and measuring discharge current through a test circuit formed when a cathode and an anode are at least partially immersed in the heat transfer fluid in a container and a voltmeter coupled to the cathode and the anode is turned on during the CWT. The method includes measuring temperature of the heat transfer fluid during the CWT, determining a current profile based on the measured discharge current, and determining a temperature profile based on the measured temperature. The method includes determining a pass/fail status and/or a rank status of the heat transfer fluid based on pass/fail criteria based on the current profile and the temperature profile during an entire duration of the CWT.