Parallel Liquid Cooling Layout for Compact Battery Thermal Control
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Solution Overview
Problem
Existing water cooling structures for batteries occupy large space and have low cooling efficiency, posing safety hazards due to overheating and potential combustion or explosion, especially in high-temperature environments.
Innovation Solution
A liquid cooling unit with a parallel structure comprising a first and second flow divider/combiner, a plate heat exchanger, radiator, and heater, connected by integrally formed refrigerant pipelines, featuring a closed fluid chamber and brushless DC water pumps, allowing flexible installation and reduced power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing water cooling structures are used, then cooling function is provided, but the structure occupies large space and has low cooling efficiency
Solution Approach 1:
The cooling system is divided into multiple independent cooling channels that can be segmented and arranged in parallel. Each channel includes a flow divider/combiner unit, plate heat exchanger, radiator, and heater, allowing the cooling function to be distributed across multiple smaller units rather than requiring a single large structure, thereby improving cooling efficiency while reducing overall space occupation.
Solution Approach 2:
The patent implements a nested structure where the refrigerant pipeline is integrally welded to form a compact integrated compressor refrigeration module. The flow divider/combiner, plate heat exchanger, radiator, and heater are nested within a unified structural framework, allowing multiple cooling components to occupy overlapping or adjacent spaces efficiently, thus reducing the total footprint while maintaining high cooling capacity.
2Power
If multiple batteries are connected in series or parallel to improve power supply performance, then power supply performance is improved, but heating phenomenon becomes severe causing safety hazards
Solution Approach 1:
The patent introduces a liquid cooling medium as an intermediary between the batteries and the heat dissipation system. The cooling fluid circulates through the plate heat exchanger and radiator, absorbing heat from the batteries and transferring it to the environment, thereby mediating the thermal management process and preventing direct overheating of the battery packs while maintaining high power output.
Solution Approach 2:
The refrigeration system utilizes phase transitions of the refrigerant in the integrally welded compressor refrigeration module. The refrigerant absorbs heat from the cooling fluid through evaporation and releases heat to the environment through condensation, efficiently removing excess heat generated by the batteries during high-power operation and preventing thermal runaway.
3Ease of manufacture
If integrally formed refrigerant pipelines are used to connect compressor, condenser, and plate heat exchanger, then installation efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the compressor, condenser, and plate heat exchanger into a single integrated compressor refrigeration module with integrally welded refrigerant pipelines. This combining of multiple components into one pre-assembled unit simplifies the installation process by reducing the number of separate parts to be installed and connected, while the integral welding is performed during manufacturing to ensure reliable refrigerant sealing and thermal transfer.
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
Improves cooling efficiency, reduces installation and maintenance complexity, and ensures safety by minimizing space occupation and power consumption while effectively managing battery thermal conditions.
Implementation Method 1
the plate heat exchanger and the radiator are configured to cool the fluid
Implementation Method 2
the heater is configured to heat the fluid
Implementation Method 3
the compressor, the condenser, the plate heat exchanger and the cooling fan are configured to cool a refrigerant
Implementation Method 4
the compressor, the condenser, the plate heat exchanger and the cooling fan are configured to cool a refrigerant
Data Source
AI summary
A liquid cooling unit includes a first flow divider/combiner, a second flow divider/combiner, a plate heat exchanger, a radiator and a heater. The plate heat exchanger, the radiator and the heater are connected in parallel between a flow dividing end of the flow divider/combiner and a flow combining end of the second flow divider/combiner. The flow dividing end of the first flow divider/combiner outputs a fluid into the plate heat exchanger, the radiator or the heater. The plate heat exchanger and the radiator cool the fluid, and the heater heats the fluid. The flow combining end of the second flow divider/combiner receives the fluid outputted by the plate heat exchanger, the radiator or the heater, and the flow dividing end of the second flow divider/combiner outputs the fluid to a battery for thermal management of the battery. The flow combining end of the first flow divider/combiner receives the fluid.