Methyl Paraffin Heat Transfer Fluids for EV Immersion Cooling
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Solution Overview
Problem
Current heat transfer fluids used in electric vehicles are unsuitable for direct immersion with batteries and electric motors due to electrical conductivity, leading to potential shorting and failure, and lack suitable thermal management properties such as high flash points and low pour points, limiting the efficiency and safety of thermal management systems.
Innovation Solution
Development of heat transfer fluids comprising methyl paraffins derived from hydrogenated linear alpha olefin dimers, which have a high Mouromtseff Number, thermal conductivity, and flash points, ensuring effective thermal management and electrical insulation, suitable for direct contact with batteries and electric motors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional heat transfer fluids (aqueous glycol solutions) are used for cooling electric vehicle components, then heat transfer capability is provided, but electrical conductivity causes shorting and failure when in contact with batteries or motors
Solution Approach 1:
The patent changes the fundamental parameter of electrical conductivity by switching from aqueous-based fluids to hydrocarbon-based methyl paraffins, achieving electrical insulation while maintaining heat transfer capability through optimized thermal properties of the hydrocarbon molecules
Solution Approach 2:
The methyl paraffin fluid acts as an intermediary substance that enables direct thermal contact between cooling system and electrical components without causing electrical shorting, mediating between the conflicting requirements of thermal efficiency and electrical safety
2Reliability
If fluorocarbon fluids are used as heat transfer fluids, then satisfactory pour point and flash point values are achieved, but burning fumes cause health and environmental problems
Solution Approach 1:
The patent employs hydrocarbon-based methyl paraffins that create a safer, less harmful environment when burned, producing combustion products that are less toxic to human health and the environment compared to fluorocarbon alternatives, while maintaining necessary flash point safety margins
3Temperature
If heat dissipation fins are added to batteries, then heat dissipation capability is improved, but vehicle weight increases lowering efficiency and performance
Solution Approach 1:
The patent extracts the heat dissipation function from passive structural additions (fins) and transfers it to the circulating fluid medium itself, allowing the battery to be cooled through fluid circulation without requiring heavy fin structures attached to the battery assembly
4Temperature
If direct immersion cooling is implemented, then optimal heat transfer is achieved, but conventional fluids cause shorting and battery or motor failure
Solution Approach 1:
The patent changes the electrical conductivity parameter of the heat transfer fluid by using hydrocarbon-based methyl paraffins instead of aqueous solutions, enabling the fluid to serve as both an efficient thermal transfer medium and an electrical insulator for direct immersion applications
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 methyl paraffin-based heat transfer fluids provide efficient thermal management, maintaining battery temperatures within safe operating ranges, reducing the risk of failure, and enhancing vehicle performance by promoting effective heat transfer without electrical conductivity issues.
Implementation Method 1
heat transfer fluids comprising methyl paraffins... promoting effective heat transfer
Implementation Method 2
heat transfer fluid may be placed in direct surface contact with a battery, electric motor or other heat-generating component to promote optimal heat transfer, including configurations in which the heat-generating component is partially or fully immersed in the heat transfer fluid
Implementation Method 3
many heat transfer fluids presently in common use are unsuitable for immersion of batteries and/or electric motors therein due to electrical conductivity of the fluid... suitable insulating heat transfer fluids
Implementation Method 4
heat transfer fluids comprising one or more methyl paraffins comprising a hydrogenated reaction product of one or more linear alpha olefin (LAO) dimers
Data Source
AI summary
Methyl paraffins formed by hydrogenating one or more LAO dimers comprising a vinylidene moiety or a trisubstituted olefin moiety may have advantageous heat transfer properties, particularly when incorporated within an electric vehicle. For example, methyl paraffins produced upon hydrogenating LAO dimers formed from one or more C6-C12 LAOS, particularly in the presence of a Hf metallocene catalyst system, may contain 12-24 carbon atoms, and collectively have a flash point of about 130° C. or above, a pour point of about −42° C. or lower, a thermal conductivity at 80° C. of about 0.165 W/m·K or higher, and a Mouromtseff number ranging from about 17,000 to about 27,000 kg/(s2.2·m0.6·K) at 80° C. Heat transfer fluids comprising such methyl paraffins may be placed in contact with a heat-generating component, such as a battery and/or motor of an electric vehicle, or within a similar type of battery system, including immersive configurations for a battery.