Integrated Battery Unit Thermal Management for Electric Vehicles
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Solution Overview
Problem
Electric vehicles face challenges with thermal management and ventilation during fast charging, leading to reduced battery performance and lifespan, as well as safety concerns due to high voltages and inaccessible charging connections, with existing solutions requiring modifications to the vehicle.
Innovation Solution
The implementation of a thermal and ventilation management system using fan modules between or next to battery pack cells, combined with a motor controller isolation system to prevent high voltages from reaching the motor drive system, and an integrated battery unit (IBU) that includes a charge port and watering solenoid valve, allowing for fast charging without vehicle modifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If fast charging is implemented to reduce recharge time, then productivity is improved, but temperature increases causing thermal management issues
Solution Approach 1:
The patent extracts the thermal management function from the battery pack case by introducing a separate, removable thermal management assembly. This assembly can be detached and replaced independently from the battery pack, allowing thermal issues to be addressed without replacing the entire battery pack, thus maintaining productivity while managing temperature.
Solution Approach 2:
The patent introduces a thermal management assembly as an intermediary component between the battery pack and the environment. This assembly includes cooling channels and fluid circulation systems that act as a mediator to transfer heat away from the battery cells during fast charging, enabling high charging rates without excessive temperature buildup.
2Ease of operation
If battery pack is permanently mounted for easy access, then ease of operation is improved, but adaptability worsens when vehicle modifications are needed
Solution Approach 1:
The patent segments the thermal management system into a separate, modular assembly that can be independently installed and removed. The thermal management assembly is designed as a distinct component from the battery pack itself, allowing it to be adapted or modified without affecting the battery pack mounting or requiring permanent vehicle modifications.
Solution Approach 2:
The thermal management assembly is designed with universal mounting features that can accommodate different battery pack configurations and vehicle types. The assembly includes standardized interfaces and mounting mechanisms that allow it to be installed on various vehicle platforms without requiring custom modifications to each vehicle, thus maintaining ease of operation while improving adaptability.
3Reliability
If battery pack case is substantially enclosed for protection, then reliability is improved, but heat dissipation worsens
Solution Approach 1:
The patent implements a nested structure where the thermal management assembly is positioned within or adjacent to the battery pack case. The cooling channels and fluid pathways are integrated into the existing battery pack structure, nesting the thermal management function within the protected enclosure while maintaining effective heat dissipation through the nested cooling elements.
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 solution effectively manages heat and prevents high voltage exposure, enhancing battery performance and safety while enabling fast charging without altering the electric vehicle's structure, thus maintaining its integrity and operational efficiency.
Implementation Method 1
The fan module includes a fan to force air across the battery pack case
Implementation Method 2
Fast charging reduces the recharge time of a 1000 Amp-hr battery... to about an hour. Fast charging thereby allows recharging to be performed... Fast charging also eliminates the need to repeatedly swap out and replace depleted battery packs with charged battery packs.
Implementation Method 3
one or more fan modules disposed between or next to cells of the battery pack... The fan module includes a fan to force air across the battery pack case
Data Source
AI summary
Methods of and apparatus for removing heat generated by cells of a battery pack. The method and apparatus may employ one or more fan modules disposed between or next to cells of the battery pack, or one or more fans directly mounted to the battery pack or battery pack case housing the cells. Further, a motor controller isolation system operates to electricity isolate the motor controller of the electric vehicle when the battery pack is being charged. The motor controller isolation system may be integrated with the integrated battery pack and thermal and ventilation system. The integrated system, or “integrated battery unit (IBU),” is preferably manufactured in a manner that requires no, modifications to the electric vehicle in which the IBU is installed.