Battery Cooling Plate Junction Layout for Leak Isolation
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Solution Overview
Problem
Existing thermal management systems for electric vehicle batteries face risks of electrical insulation faults and potential fires due to leaks of heat transfer fluids, which can lead to explosions, especially when liquid connections are used within the battery pack.
Innovation Solution
A thermal management system with a fluid collection box around connection zones to contain any leaking heat transfer fluid, preventing it from contacting battery cells, and incorporating sensors to detect leaks and alert the vehicle's on-board computer for maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heat transfer fluid connections are used within the battery pack to increase heat exchange efficiency, then thermal management performance is improved, but the risk of electrical insulation faults and fires increases due to potential fluid leaks
Solution Approach 1:
The patent divides the battery pack into distinct sealed compartments: a first sealed space containing electrical components and a second sealed space containing heat transfer fluid connections. This segmentation prevents fluid from contacting electrical components even if leaks occur, resolving the contradiction between thermal management efficiency and electrical safety.
Solution Approach 2:
The patent introduces a sealed partition wall as an intermediary barrier between the heat transfer fluid and electrical components. This mediator allows thermal management to function effectively while preventing direct contact between fluid and electrical elements, thus eliminating the insulation fault risk.
2Area of stationary object
If multiple heat exchangers are added to increase heat exchange surface area, then thermal regulation capability is improved, but the complexity of fluid connections and leak risk points increases
Solution Approach 1:
The patent combines multiple heat exchanger units into a single integrated heat exchange plate structure with unified fluid connections. This merging reduces the number of separate connection points while maintaining adequate heat exchange surface area, thereby reducing complexity and potential leak points.
Solution Approach 2:
The heat exchange plate is designed as a multi-functional component that serves both thermal management and structural sealing functions. The single plate integrates multiple heat exchange surfaces while providing a unified sealed connection interface, reducing overall system complexity.
3Use of energy by moving object
If liquid connections are used inside the battery pack for thermal management, then heat transfer efficiency is improved, but the risk of fires and explosions increases due to potential fluid leakage
Solution Approach 1:
The patent extracts the heat transfer fluid from the electrical environment by placing it in a separate sealed space. This removal of the fluid from proximity to electrical components eliminates the fire and explosion risk while preserving heat transfer efficiency through the sealed heat exchange interface.
Solution Approach 2:
The patent implements preliminary protective sealing measures by creating sealed spaces before any leak could occur. The sealed partition walls and gaskets are pre-installed to prevent fluid escape, thereby preventing fire and explosion hazards before they can materialize.
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
Prevents electrical insulation faults and potential fires by containing leaks within a separate volume, ensuring safe operation and allowing for timely maintenance to avoid battery pack damage.
Implementation Method 1
at least one plate comprising at least a heat transfer fluid channel between a fluid inlet and a fluid outlet of said plate
Implementation Method 2
a heat transfer liquid such as glycol water is regularly used. This liquid circulates in the plates or tubes in contact with the cells, and there is a heat exchange between this heat transfer liquid and the cells
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present invention relates to a thermal management system (200) for an electric component, which system is capable of emitting heat during the operation of the electric component, in particular for an electrical energy storage module, comprising: - at least one housing (2) intended to receive at least one electric component, in particular a plurality of such housings arranged in parallel; - at least one heat exchange plate (210) extending over at least one portion of the surface of the lateral face of the housing, the at least one plate comprising at least one heat transfer fluid channel between a fluid inlet (211) and a fluid outlet (212) of the plate (210); - a supply duct configured to supply the plate with heat transfer fluid via the fluid inlet of the plate and a discharge duct configured to discharge the heat transfer fluid from the plate via the fluid outlet of the plate, - a casing (300) defining the housing(s) and receiving the heat exchange plate and the supply and discharge ducts, - a fluid-collecting box (215) arranged to collect fluid from a possible fluid leakage at the junction between the fluid inlet and the fluid outlet of the plate and the associated supply and discharge ducts, so as to prevent said leaked fluid from dripping into a bottom of the casing.