Offset Battery Cell Heat Exchanger for Thermal Management
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Solution Overview
Problem
There is a need for improved battery modules and systems for electric vehicles that address the challenges associated with nickel-metal-hydride (NiMH) and lithium-ion battery systems, particularly in terms of temperature regulation and manufacturing, to enhance performance, efficiency, and cost-effectiveness.
Innovation Solution
A battery module design featuring electrochemical cells arranged in offset rows with a heat exchanger configured to allow fluid flow between the cells, providing efficient cooling and heating, and a modular assembly that includes a cell supervisory controller and bus bar assembly for thermal management and electrical connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If lithium-ion batteries are used to increase charge density and specific power, then vehicle range and power performance are improved, but temperature regulation challenges increase and manufacturing complexity increases
Solution Approach 1:
A heat exchanger is introduced as an intermediary component between the lithium-ion battery cells to facilitate thermal management. The heat exchanger includes a fluid flow path that contacts the battery cells, enabling efficient heat transfer from the cells to the flowing fluid, thus regulating battery temperature during operation.
Solution Approach 2:
The patent employs a fluid-based thermal management system where a coolant flows through channels in the heat exchanger. This hydraulic approach enables active cooling of the battery cells by circulating fluid that absorbs and removes excess heat generated during battery operation.
2Quantity of substance
If lithium-ion batteries are used to increase charge density, then vehicle range is improved, but manufacturing challenges increase
Solution Approach 1:
The battery system is divided into modular units with standardized heat exchanger components that can be integrated with battery cell assemblies. This segmentation allows for simplified manufacturing processes where pre-assembled modules can be manufactured separately and then combined, reducing overall manufacturing complexity.
3Temperature
If heat exchanger is added for thermal management, then temperature regulation is improved, but device complexity increases
Solution Approach 1:
The heat exchanger is integrated directly with the battery cell structure, merging the thermal management function with the battery assembly itself. This integration eliminates the need for separate, complex thermal management systems by combining cooling channels within the battery housing or directly contacting the cell surfaces.
Solution Approach 2:
The heat exchanger design serves multiple functions: it provides thermal management for the battery cells, structurally supports the battery assembly, and facilitates fluid distribution. This multi-functionality reduces the number of separate components needed, thereby simplifying the overall system despite adding thermal management capability.
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 enhances the performance and reliability of battery systems by improving temperature regulation and reducing costs through efficient thermal management and modular design, allowing for increased vehicle range and reduced weight, while accommodating the unique challenges of lithium-ion batteries.
Implementation Method 1
a heat exchanger configured to allow a fluid to flow through the heat exchanger... an external surface of the heat exchanger contacts a portion of each of the plurality of electrochemical cells
Data Source
AI summary
A battery module includes a plurality of electrochemical cells arranged in a first row and a second row offset from the first row. The battery module also includes a heat exchanger configured to allow a fluid to flow through the heat exchanger. The heat exchanger is disposed between the first and second rows of cells and has a shape that is complementary to the cells in the first and second rows of cells so that an external surface of the heat exchanger contacts a portion of each of the plurality of electrochemical cells. The heat exchanger is configured to route the fluid between an inlet and an outlet such that a path of the fluid flow includes a plurality of adjacent fluid flow segments.