Multi-Wall Battery Cooling via Segmented Distributors
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Solution Overview
Problem
During rapid charging of electrical energy storage devices in vehicles, such as battery cells, excessive heat generation poses a challenge for maintaining optimal temperature (between 20°C and 40°C) to ensure reliability, performance, and lifespan, while existing cooling systems struggle to efficiently manage high thermal power dissipation.
Innovation Solution
A thermal regulation device comprising heat exchange walls with channels and separate distributor elements that enhance heat transfer between a heat transfer fluid and electrical components, allowing for cooling of multiple faces of electrical energy storage modules, thereby increasing the heat exchange surface area while minimizing size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a cold plate with heat transfer fluid channels is used for cooling battery cells during rapid charging, then heat extraction capability is improved, but the system size and complexity increase
Solution Approach 1:
The patent transitions from conventional single-face cold plate cooling to multi-face cooling by adding distributor elements that enable heat transfer fluid circulation through channels in multiple walls (first wall, second wall, third wall) of the battery module. This dimensional expansion of cooling surfaces dramatically increases heat extraction capability while maintaining a compact form factor, directly resolving the contradiction between power and volume.
Solution Approach 2:
The cooling system is segmented into multiple independent cooling circuits, each serving different walls of the battery module. The first distributor element serves the first and second walls, while the second distributor element serves the second and third walls. This segmentation allows optimized heat extraction from each face independently, achieving high overall cooling power without requiring a single large complex system.
2Area of stationary object
If heat exchange surface area is increased to manage high thermal power during fast charging, then cooling efficiency is improved, but device complexity increases
Solution Approach 1:
The distributor elements serve multiple walls simultaneously through integrated channel designs. The first distributor element provides fluid distribution to both the first wall and second wall channels, and the second distributor element serves the second wall and third wall channels. This merging approach increases the effective heat exchange surface area while avoiding the complexity of entirely separate cooling systems for each wall.
Solution Approach 2:
The distributor elements perform multiple functions: they distribute heat transfer fluid to multiple different walls, collect fluid from multiple walls, and provide structural support for the cooling system architecture. This multi-functionality increases heat exchange surface area utilization while minimizing the number of separate components required, thereby reducing overall device complexity.
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
Effectively regulates the temperature of electrical components by increasing heat exchange capacity, ensuring reliable operation and extended lifespan during rapid charging by efficiently managing high thermal power dissipation.
Implementation Method 1
a heat transfer fluid runs through the channels. The fluid is then in heat exchange with the heat exchange plate. It will then be understood that the heat exchange plate, by conduction, allows heat transfer between the fluid and the electrical component
Implementation Method 2
a heat transfer fluid runs through the channels... the first and second channels being arranged to be traversed by a heat transfer fluid
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3
AI summary
Thermal regulation device (1) for at least one electrical component (2) which is capable of discharging heat during operation thereof, this component being particularly an electrical energy storage element or an electronic power device, the device being particularly designed to be mounted on a motor vehicle, the device comprising: a first wall (3) which follows a first plane and comprises a first channel (31), the ends of the channel (31) opening into a portion (61) of a first end of the first wall (3), respectively, a second wall (4) which follows a second plane and comprises a second channel (41), the ends (42) of the channel (41) opening into a portion (62) of a first end of the second wall (4), respectively, at least a first fluid distribution element (5) which is designed to be in fluid communication with at least one of the channels (31, 41), the first channel (31) and second channel (41) being designed to be passed through by a heat transfer fluid, the first and second planes intersecting and the distribution element (5) being different from the first wall (3) and second wall (4) and being mounted on at least the portion (61, 62) of the first end of the first wall (3) and second wall (4).