Corrugated Battery Cooling Pipe for Compact EV Thermal Management
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Solution Overview
Problem
Conventional cooling methods for high-voltage, high-capacity batteries in electric vehicles increase the volume and part count, leading to cost rises and inefficient use of space due to the need for separate heat sinks or passage gaps.
Innovation Solution
A corrugated pipe design for the cooling pipe that generates vortexes in the cooling fluid, reducing its velocity and enhancing cooling efficiency by integrating with the radiator and battery modules, using aluminum for improved thermal conductivity and reduced material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If indirect air-cooling or water-cooling is used with a heat sink fin, then heat exchange capability is improved, but the volume of batteries increases and the number of parts increases resulting in cost rise
Solution Approach 1:
The cooling pipe is integrated directly into the battery module structure, merging the cooling function with the battery housing. This eliminates the need for separate heat sink fins and external cooling passages, reducing overall battery volume while maintaining effective heat exchange capability through direct thermal contact between the cooling pipe and battery cells.
2Temperature
If indirect air-cooling or water-cooling is used with a heat sink fin, then heat exchange capability is improved, but the number of parts increases resulting in cost rise
Solution Approach 1:
The cooling pipe is integrated directly into the battery module structure, merging the cooling function with the battery housing. This eliminates the need for separate heat sink fins and external cooling passages, reducing the number of parts and simplifying the overall system architecture while maintaining effective heat exchange capability.
Solution Approach 2:
The cooling pipe serves multiple functions simultaneously: it acts as both a structural component of the battery module and a thermal management component. This multi-functionality reduces the need for dedicated cooling parts, thereby reducing part count and manufacturing cost while maintaining heat exchange effectiveness.
3Temperature
If direct air-cooling is used by sending air to the surface of the battery module, then cooling capability is improved, but the overall volume of the batteries increases because a passage gap for cooling needs to be secured between battery modules
Solution Approach 1:
The cooling pipe is integrated directly into the battery module structure, merging the cooling function with the battery housing. This eliminates the need for separate cooling passage gaps between modules, reducing overall battery volume while maintaining effective cooling capability through direct thermal contact between the cooling pipe and battery cells.
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 corrugated pipe design improves cooling efficiency by generating vortexes, reducing fluid velocity, and maintaining compactness while minimizing material and space requirements, thus optimizing battery performance and lifespan.
Implementation Method 1
a corrugated pipe that may be integrally formed with the body pipe and formed in the form of one or more corrugations between the inlet and the outlet... the corrugated pipe may be formed on the cooling pipe to generate vortexes of a cooling fluid flowing from a radiator to the cooling pipe
Implementation Method 2
cool the battery modules... a cooling system for controlling high-temperature heat generated by a high-voltage, high-capacity battery must be built in an electric or hybrid vehicle
Data Source
AI summary
The present disclosure relates to a cooling pipe of an electric vehicle battery that is coupled to one side and the other side of a radiator, passes between battery modules of which a battery pack consists, and cools the battery modules, including: a body pipe that is formed in a pipe shape so that a flow path through which a cooling fluid flows is formed therein and has an inlet on one side and an outlet on the other side, wherein the inlet is coupled to one side of the radiator and the outlet is coupled to the other side thereof; and a corrugated pipe that is integrally formed with the body pipe and is formed in the form of one or more corrugations between the inlet and the outlet.