Multi-PCM Battery Thermal Management via Nested Shell Design
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Solution Overview
Problem
Electric vehicle batteries face challenges in thermal management due to varying heat generation and cooling requirements across cells, with active cooling methods being inefficient and insufficient in heat removal capacity, leading to temperature variations and potential battery degradation.
Innovation Solution
A thermal management system utilizing multiple phase change materials (PCMs) in an array of unit cells, where each cell has a primary and secondary shell thermally coupled via a heat bridge, effectively absorbing and releasing heat to maintain optimal battery temperature, complementing active cooling methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If active cooling methods are used to remove heat from battery cells, then heat removal capacity is improved, but system complexity and inefficiency increase
Solution Approach 1:
The patent employs phase change materials (PCMs) that absorb and release heat during phase transitions (solid-liquid-solid). The primary PCM in the first shell and secondary PCM in the second shell work together to passively manage battery thermal conditions, eliminating the need for complex active cooling systems while maintaining effective heat removal capacity.
Solution Approach 2:
The thermal management system operates autonomously using the inherent thermal properties of PCMs. The system self-regulates battery temperature through phase change heat absorption during charging/discharging cycles without requiring external control systems, pumps, or fans, thereby reducing system complexity while maintaining heat removal capability.
2Adaptability or versatility
If a single phase change material is used in the thermal management system, then device complexity is reduced, but adaptability to varying heat generation rates is insufficient
Solution Approach 1:
The patent uses different PCMs with specific phase change temperatures tailored to different thermal management needs. The primary PCM addresses lower temperature ranges while the secondary PCM handles higher temperature scenarios, creating localized thermal management zones that adapt to varying heat generation rates during different battery operating conditions.
Solution Approach 2:
The system combines multiple PCM materials with complementary thermal properties in a composite thermal management structure. This composite approach enables the system to handle a broader range of thermal conditions and heat generation rates, improving adaptability while the integrated design keeps the overall structure manageable.
3Adaptability or versatility
If multiple phase change materials in separate shells are used, then adaptability and heat absorption capability are improved, but device complexity increases
Solution Approach 1:
The patent implements a nested shell structure where the second shell containing secondary PCM is positioned within or adjacent to the first shell containing primary PCM. This nested arrangement allows multiple PCMs to work together in a compact configuration, improving heat absorption capability across different temperature ranges while minimizing the increase in device complexity through space-efficient design.
Solution Approach 2:
The thermal management system is divided into segmented functional zones with primary and secondary PCMs handling different thermal management tasks. This segmentation allows each PCM to be optimized for specific temperature ranges and heat generation scenarios, improving overall adaptability while the modular segmented structure makes the system more manageable and less complex than a monolithic design.
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 extends the operational duration and distance of electric vehicles by efficiently managing heat, reducing temperature variations, and enhancing user experience through effective heat absorption and rejection, thus prolonging battery life and improving performance.
Implementation Method 1
Each unit cell includes a primary shell comprising a primary phase change material (PCM), and a secondary shell comprising a secondary PCM that is thermally coupled to the primary shell
Implementation Method 2
a secondary shell comprising a secondary PCM that is thermally coupled to the primary shell via a heat bridge
Implementation Method 3
This waste heat can be transferred to a heat exchanger and rejected to the atmosphere to cool the electric battery
Data Source
AI summary
A battery module including a battery cell and a thermal management system for removing heat from the battery cell. The thermal management system includes two or more unit cells in an array. Each unit cell includes a primary shell comprising a primary phase change material (PCM), and a secondary shell comprising a secondary PCM that is thermally coupled to the primary shell. The battery cell is thermally coupled to the primary shell at a heat transfer interface and the secondary shells of adjacent unit cells in the array are separate.