EV Battery Coolant Manifold with Branch Flow Restrictors
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Solution Overview
Problem
Existing coolant manifold systems for electric vehicles often result in non-uniform coolant distribution to battery modules, leading to temperature discrepancies and reduced thermal management efficiency.
Innovation Solution
A coolant manifold system with flow restrictors and a hierarchical conduit structure that evenly distributes coolant across multiple battery modules, ensuring consistent heating and cooling rates by controlling coolant flow through a network of primary, secondary, and tertiary conduits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple parallel coolant distribution system is used, then the device complexity is reduced, but the coolant distribution uniformity deteriorates leading to temperature discrepancies
Solution Approach 1:
The patent applies local quality by introducing flow restrictors at specific locations within the coolant manifold system. These restrictors create localized flow resistance in branches that would otherwise receive excessive coolant, thereby balancing the overall distribution. The flow restrictors are strategically positioned to address specific imbalances in different manifold branches, ensuring uniform coolant delivery to all battery modules without requiring complete system redesign.
2Stability of the object's composition
If flow restrictors are added to control coolant distribution, then the coolant distribution uniformity is improved, but the device complexity increases
Solution Approach 1:
The patent segments the coolant distribution control function by introducing individual flow restrictors for different manifold branches. Each flow restrictor independently controls the flow to specific battery modules or groups of modules, allowing precise adjustment of coolant distribution. This segmentation enables targeted flow control without affecting other branches, achieving uniform distribution while keeping each control element simple and modular.
3Reliability
If coolant flow is increased to improve cooling efficiency, then the thermal management efficiency is improved, but the power consumption increases
Solution Approach 1:
The patent changes the flow resistance parameter within the coolant manifold system by incorporating flow restrictors. This parameter modification allows the system to achieve uniform coolant distribution at lower flow rates, improving thermal management efficiency without requiring high pump power. The flow restrictors create optimal flow conditions that maximize heat transfer efficiency while minimizing the energy required to circulate coolant through the battery modules.
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 achieves more uniform coolant distribution and temperature regulation across battery modules, enhancing thermal management efficiency and reducing power consumption by minimizing temperature discrepancies.
Implementation Method 1
a plurality of flow restrictors each restricting coolant flow to a respective subset of the branch conduits
Implementation Method 2
a cooling structure configured to channel a liquid coolant through the battery module for thermally regulating temperature of the battery cell(s)
Data Source
AI summary
In one aspect, an electric vehicle comprises a plurality of battery modules, each of the battery modules having a respective coolant inlet, a coolant source, and a coolant inlet manifold configured to supply coolant from the coolant source to each of the plurality of coolant inlets in parallel. The manifold includes a coolant supply conduit, a plurality of branch conduits branching from the coolant supply conduit, and a plurality of flow restrictors. Each of the branch conduits is fluidically coupled to the coolant inlet of an associated respective one of the battery modules. Each of the flow restrictors restricts coolant flow to a respective subset of the branch conduits. In another aspect, the manifold includes a primary conduit, a plurality of secondary conduits branching from the primary conduit, and for each of the secondary conduits, a plurality of tertiary conduits branching from the secondary conduit.