Multi-Stage Cascaded TEC Packaging for Battery Temperature Uniformity
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Solution Overview
Problem
Conventional air cooling systems in battery backup units (BBUs) face challenges in maintaining uniform temperatures across battery cells, leading to thermal gradients and performance issues, which complicates system design and reduces energy density.
Innovation Solution
A multi-stage cascaded thermoelectrical cooler (TEC) package is integrated into the BBU, where TECs are strategically attached to battery cells in different regions, powered by the discharging converter circuit during discharge cycles, to enhance heat transfer and maintain temperature uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a complex air cooling system is used to regulate temperatures of battery cells, then temperature uniformity is improved, but device complexity and cost increase
Solution Approach 1:
The battery module is divided into multiple zones along the airflow direction, with different numbers of cooling channels assigned to each zone. The first zone has fewer cooling channels while subsequent zones have progressively more channels, creating a segmented cooling strategy that addresses temperature uniformity without requiring a fully complex system throughout
Solution Approach 2:
Different regions of the battery module are provided with different cooling intensities according to their specific thermal needs. Zones farther from the air inlet receive more cooling channels to compensate for the progressively warmer airflow, implementing local quality adjustment to achieve global temperature uniformity
2Temperature
If more cooling air is flowed through battery cells to reduce temperature gradient, then temperature uniformity is improved, but available space for battery cells decreases
Solution Approach 1:
The cooling system is segmented into multiple independent cooling channels distributed across different zones rather than using a single large cooling air flow path. This segmentation allows efficient use of space by creating dedicated cooling pathways that maximize cooling effectiveness within the available volume
Solution Approach 2:
The cooling approach transitions from increasing airflow volume in one dimension to distributing cooling channels across multiple spatial dimensions and zones. By adding cooling channels in the vertical and lateral directions rather than simply increasing horizontal airflow, the system achieves better temperature uniformity without sacrificing battery cell space
3Loss of energy
If cooling air flows through battery cells, then heat transfer is improved, but thermal gradient between cells in different rows increases
Solution Approach 1:
Different zones along the airflow path are equipped with different numbers of cooling channels to compensate for the progressive heating of air. Zones farther from the inlet receive more cooling channels, creating a non-uniform cooling distribution that counteracts the non-uniform heating effect and maintains temperature uniformity across all rows
Solution Approach 2:
The cooling channel distribution is designed based on feedback from the thermal characteristics of the system. The progressive increase in cooling channels in downstream zones compensates for the accumulated thermal effects, creating a self-balancing cooling strategy that maintains temperature uniformity despite the directional airflow
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 solution simplifies the design, reduces costs, and maintains high energy density by effectively controlling temperature differences among battery cells, ensuring consistent performance and safety.
Implementation Method 1
a multi-stage cascaded thermoelectrical cooler (TEC) package for enhancing transfer of heat in battery cells
Data Source
AI summary
A multi-stage cascaded thermoelectrical cooler (TEC) package is used in conjunction with an air cooling system to control temperature of battery cells in a battery module such that the temperature differences stay within a predetermined range. Battery cells in the battery module are divided into one or more regular sections and one or more TEC enhancing sections. A regular section and a TEC enhancing section can use different types of battery cell holders to assemble the battery cells. TECs in the TEC package are integrated into each enhancing section, where each stage of the TEC package is attached to one or more battery cells in a different region of the enhancing section. A higher stage, which is more powerful in enhancing heat transfer and extracting heat from battery cells, is attached to one or more battery cells in a section closer to the air outlet. The TEC package is powered by a discharging convertor circuit of the battery module.