Integrated Liquid Cooling Module for EV Battery Maintenance
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Solution Overview
Problem
Conventional liquid cooling systems for electric vehicle batteries face challenges in maintenance due to their design, particularly for modularized battery modules, where strip-shaped metal cooling tubes are not applicable and cooling plates require complex pipeline connections, leading to leakage and space inefficiencies.
Innovation Solution
A liquid cooling module with an integrated cooling plate and pump block forming a self-contained circulation loop, featuring a heat exchange chamber and miniature pump, which eliminates the need for external components and simplifies maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling plates with pipelines are used to cool battery cells, then heat dissipation effectiveness is improved, but maintenance difficulty increases due to complex pipeline connections and leakage risks
Solution Approach 1:
The cooling system is divided into independent modular units, each comprising a cooling plate with integrated pump block and circulation loop. Each module can be independently maintained or replaced without affecting other battery cells, eliminating the need to disconnect complex pipeline networks during maintenance.
Solution Approach 2:
The pump block is integrated directly with the cooling plate to form a unified modular component. The circulation loop is contained within each module, merging the cooling function and pumping function into a single maintainable unit that eliminates external pipeline connections.
2Area of stationary object
If strip-shaped metal cooling tubes are used for large battery packs, then cooling coverage is improved, but adaptability to modularized battery modules deteriorates
Solution Approach 1:
The cooling system is segmented into standardized modular units that can be scaled and configured to match different battery pack sizes and arrangements. Each module serves a specific battery cell or group of cells, allowing flexible adaptation to various modularized battery configurations.
Solution Approach 2:
The modular cooling plate design with integrated pump block serves as a universal cooling solution that can be applied across different battery cell types and arrangements. The standardized interface and dimensions allow the same module design to be used in various battery pack configurations.
3Power
If external pumps and heat exchangers are used for liquid cooling circulation, then heat dissipation capability is improved, but space efficiency deteriorates
Solution Approach 1:
The pump and heat exchange functions are merged into a compact integrated pump block that is directly attached to the cooling plate. This eliminates the need for separate external pumps and heat exchangers, significantly reducing the space required for the cooling system while maintaining effective heat dissipation capability.
Solution Approach 2:
The pump block is nested within or directly integrated with the cooling plate structure, with the circulation loop contained within the modular unit. This nested arrangement minimizes the overall volume occupied by the cooling system components.
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
This design enhances maintenance efficiency by allowing independent cooling for each battery, reducing space requirements and preventing coolant leakage, thus improving the reliability and efficiency of electric vehicle battery cooling systems.
Implementation Method 1
the heat of the batteries is transferred to a liquid cooling circulation loop
Implementation Method 2
the glycol coolant is distributed throughout the battery pack to cool the battery cell
Implementation Method 3
a pump block, integrated with the cooling plate and including a pump
Data Source
AI summary
A liquid cooling module comprises a cooling plate, including a plurality of cooling channels for liquid flowing, and a pump block, integrated with the cooling plate and including a pump and a heat exchange chamber connecting to the plurality of cooling channels of the cooling plate, to form a circulation loop.