EV Battery Air Cooling Layout for Multi-Housing Thermal Control
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Solution Overview
Problem
Conventional cooling systems for electric vehicles are inadequate for cooling additional components beyond engine components, as they typically rely on liquid cooling for engine components and air cooling for operators, failing to address the cooling needs of other critical components.
Innovation Solution
An air cooling system comprising a compressor, condenser, evaporator coils, and blowers is designed to efficiently cool battery modules by directing cooled air through dedicated housings, with specific airflow volumes and distributions to ensure effective cooling of multiple battery banks and electronic components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional liquid cooling is used for engine components, then engine cooling effectiveness is improved, but it cannot cool additional components such as battery modules
Solution Approach 1:
The air cooling system is designed to serve multiple cooling needs simultaneously - it cools battery modules, electronic components, and provides cabin cooling through the same evaporator coils and blower assembly, making the system universally applicable to various thermal management requirements in the electric vehicle
2Device complexity
If air cooling is used for operators, then simplicity is improved, but it cannot effectively cool critical components like battery modules
Solution Approach 1:
The air cooling system is segmented into distinct airflow paths with separate evaporator coils for different components - one set of coils for battery modules with dedicated blowers, and another set for cabin cooling, allowing each segment to be optimized for its specific cooling requirements while maintaining overall system simplicity
Solution Approach 2:
The evaporator coils act as intermediaries that transfer thermal energy from the air stream to the battery modules and electronic components. The cool air generated by the compressor-condenser-evaporator cycle serves as an intermediary cooling medium that can be distributed to multiple locations through ducts and blowers
3Adaptability or versatility
If cooling air is distributed to multiple battery housings, then cooling coverage is improved, but airflow volume per housing may be insufficient
Solution Approach 1:
The cooling system segments the airflow distribution by providing dedicated blowers for each battery housing and electronic component housing. This segmentation ensures that each housing receives sufficient airflow volume independently, while the overall system maintains broad cooling coverage across all components
Solution Approach 2:
The system applies local quality by tailoring the airflow characteristics to each specific housing - larger battery housings receive higher airflow volumes through dedicated blowers, while smaller electronic component housings receive appropriately scaled airflow, ensuring optimal cooling effectiveness at each location rather than using a uniform distribution approach
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 provides efficient cooling of battery modules and electronic components, optimizing airflow to maintain optimal operating temperatures and reduce thermal stress, thereby enhancing the performance and longevity of these components.
Implementation Method 1
a compressor
Implementation Method 2
a condenser
Implementation Method 3
a first evaporator coil that includes a first side at which warm air is received and a second side at which cool air exits after having passed through the first evaporator coil
Implementation Method 4
a first blower to direct a first portion of the cool air from the second side of the first evaporator coil into the first battery housing
Data Source
AI summary
A vehicle includes a first battery housing to house a plurality of first battery modules, a second battery housing to house a plurality of second battery modules, and an air cooling system to cool the plurality of first battery modules and the plurality of second battery modules. The air cooling system includes a compressor, a condenser, a first evaporator coil that includes a first side at which warm air is received and a second side at which cool air exits after having passed through the first evaporator coil, and a second evaporator coil that includes a first side at which warm air is received and a second side at which cool air exits after having passed through the second evaporator coil.