Deformable Cooling Conduits for Battery Pack Impact Detection
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Solution Overview
Problem
The risk of battery pack fires in hybrid and electric vehicles due to thermal runaway events, which can be triggered by damage from road debris or collisions, poses a significant challenge in maintaining consumer confidence and safety.
Innovation Solution
A detection system utilizing deformable cooling conduits with integrated sensors between the battery pack and the enclosure panel, which absorb impact energy and monitor coolant flow or pressure to detect potential damage, triggering responses such as warning indicators, coolant flow modifications, or fire control systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If deformable cooling conduits are used to absorb impact energy, then the battery pack's resistance to thermal runaway is improved, but the device complexity increases
Solution Approach 1:
The cooling conduits are designed to serve dual functions: (1) their primary function of cooling the batteries through coolant flow, and (2) a secondary function of acting as deformable impact absorbers that detect collisions and mitigate damage. This multi-functionality allows the same component to address both thermal management and safety concerns without adding separate dedicated impact absorption mechanisms, thereby improving reliability while limiting the increase in device complexity.
Solution Approach 2:
The cooling conduits are designed to automatically detect impact events through changes in coolant flow characteristics and autonomously initiate mitigation responses (such as activating warning systems or fire suppression) without requiring separate sensors or complex detection systems. The coolant flow itself serves as the detection mechanism, and the system self-regulates based on the detected conditions, reducing the need for additional active components.
2Measurement precision
If sensors are integrated into the cooling conduits to monitor coolant characteristics, then the detection precision is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The sensors are integrated directly into the existing cooling conduit structure rather than being separate components. This merging of the sensing function with the cooling conduit structure allows impact detection capabilities to be embedded within the already-manufactured cooling system, achieving precise impact detection while avoiding the need for separate high-precision sensor integration processes.
Solution Approach 2:
The system replaces complex mechanical impact sensors with a fluid-based detection mechanism. By monitoring changes in coolant flow characteristics (such as flow rate, pressure, or turbulence) caused by conduit deformation during impact, the system achieves precise impact detection using relatively simple flow sensors that can be easily integrated into the coolant circulation system without stringent manufacturing precision requirements.
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 effectively reduces the likelihood of catastrophic thermal runaway events by detecting damage and initiating appropriate responses to mitigate potential battery pack damage, thereby enhancing safety and reliability.
Implementation Method 1
The cooling conduits, which include one or more coolant channels containing a coolant, are configured to deform and absorb impact energy when an object strikes the lower surface of the lower battery pack enclosure panel
Implementation Method 2
The cooling conduits, which include one or more coolant channels containing a coolant, are configured to deform and absorb impact energy when an object strikes the lower surface of the lower battery pack enclosure panel
Implementation Method 3
One or more sensors incorporated into the deformable cooling conduits monitor a coolant characteristic such as coolant flow rate or pressure
Implementation Method 4
One or more sensors incorporated into the deformable cooling conduits monitor a coolant characteristic such as coolant flow rate or pressure
Implementation Method 5
A thermal insulator may be interposed between the conduits and the lower enclosure panel
Implementation Method 6
A layer of thermally conductive material may be placed in contact with each of the deformable cooling conduits
Data Source
AI summary
A system and a method are provided for detecting when a vehicle mounted battery pack is damaged due to an impact with a piece of road debris or other obstacle. The system utilizes a plurality of cooling conduits located between the lower surface of the batteries within the battery pack and the lower battery pack enclosure panel. The cooling conduits are configured to deform and absorb impact energy when an object strikes the lower battery pack enclosure panel. When the cooling conduits deform, a change in coolant flow/pressure occurs that is detectable by one or more sensors integrated into the conduit's coolant channels. A system controller, coupled to a sensor monitoring subsystem, may be configured to provide any of a variety of responses when cooling conduit deformation is detected.