EV Battery Pack Multi-Mode Cooling System with Segmented Conduits
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Solution Overview
Problem
Existing thermal management systems for electric vehicles fail to efficiently maintain battery packs within their desired operating temperature range while optimizing overall vehicle operating efficiency, particularly in varying ambient conditions and low-speed operations.
Innovation Solution
A multi-mode thermal management system utilizing separate conduits for battery heat removal and enclosure cooling, with a thermal insulator, a vehicle-mounted radiator, and a valve controller to regulate coolant flow, including a refrigeration subsystem and impact-absorbing conduits, to manage temperature and protect the battery pack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional thermal management system with a single cooling loop is used, then the system structure is simple, but the system cannot efficiently maintain battery temperatures within the desired range while optimizing overall vehicle operating efficiency
Solution Approach 1:
The thermal management system is divided into two separate cooling loops: a first cooling loop dedicated to battery cooling and a second cooling loop for HVAC subsystem cooling. This segmentation allows each loop to be optimized for its specific function, improving battery temperature control efficiency while maintaining manageable system complexity through modular design
Solution Approach 2:
The system incorporates a dual mode valve that enables the thermal management system to operate in two configurations: parallel mode where both cooling loops operate independently, and series mode where they operate sequentially. This multi-functionality allows the system to adapt to different operating conditions, optimizing overall vehicle efficiency while maintaining reliable battery temperature control
2Temperature
If a large radiator is mounted within or directly to the battery pack, then battery cooling efficiency is maximized, but the vehicle's aerodynamics are degraded and overall operating efficiency is reduced
Solution Approach 1:
The radiator is extracted from the battery pack and mounted remotely on the vehicle. This separation allows the battery pack to maintain a compact, aerodynamic design while the radiator is positioned in an optimal location for heat dissipation. The first cooling loop uses insulated conduits to transport coolant between the battery and radiator, maintaining cooling efficiency without compromising vehicle aerodynamics
Solution Approach 2:
Thermally insulating material is introduced as an intermediary between the battery and the cooling conduits. This insulation prevents unwanted heat transfer while allowing the coolant to efficiently absorb heat from the battery through the insulated conduits, maintaining effective cooling despite the physical separation between battery and radiator
3Object-affected harmful factors
If the thermal management system does not account for impact protection, then the system structure is simpler, but the battery pack is vulnerable to damage from impacts
Solution Approach 1:
The cooling conduits are designed with impact-absorbing characteristics, allowing them to deform and absorb impact energy when subjected to external forces. This beforehand cushioning protects the battery pack from damage while the conduits remain functional, and the system includes provisions for detecting conduit deformation to trigger appropriate responses
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 system effectively maintains battery temperatures within the desired range, reduces radiator size for improved aerodynamics, and provides enhanced protection against impacts, ensuring efficient vehicle operation and battery safety.
Implementation Method 1
a first plurality of conduits that are adjacent to, and thermally coupled to, the batteries contained within the electric vehicle's battery pack
Implementation Method 2
a thermal insulator interposed between the first and second pluralities of conduits
Implementation Method 3
a radiator that is mounted to the vehicle and that is remotely located relative to the battery pack enclosure
Implementation Method 4
a radiator that is mounted to the vehicle and that is remotely located relative to the battery pack enclosure
Data Source
AI summary
A multi-mode thermal management system is provided for use with the battery pack of an electric vehicle, the system utilizing the surface area of the battery pack to remove battery pack heat. The system includes two sets of coolant conduits separated by a thermal insulator, with one set of the coolant conduits thermally coupled to the batteries and the other set of coolant conduits coupled to at least one thermally conductive battery pack surface. A valve controller is used to optimize system performance by coupling the battery cooling conduits to the battery pack heat withdrawal conduits and/or a separate radiator and/or a heat exchanger coupled to a refrigeration subsystem.