Thermally Activated Valve Battery Pack Thermal Management
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Solution Overview
Problem
High-voltage battery packs generate substantial heat during operation, degrading efficiency and structural integrity, and existing thermal management systems may fail to effectively regulate temperature, especially in critical thermal events.
Innovation Solution
A thermal management system with a coolant line and thermally activated valves that spray coolant onto battery modules when temperature exceeds a threshold, using a thermally activated material with a melting point above normal operating temperatures but below critical temperatures to facilitate coolant flow without requiring temperature sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional thermal management systems with temperature sensors are used, then temperature regulation can be achieved, but system complexity and potential failure points increase
Solution Approach 1:
The thermal management system uses thermally-activated valves that automatically open in response to temperature increases without requiring external sensors or control systems. The valves contain a thermally-activated material that changes state at a predetermined temperature, triggering coolant flow directly in response to thermal conditions.
Solution Approach 2:
The patent replaces electronic temperature sensing and control systems with a purely thermal-mechanical response system. The thermally-activated material undergoes phase change or expansion at critical temperatures, mechanically opening the valve to allow coolant flow, eliminating the need for sensors, processors, and electronic actuators.
2Reliability
If coolant lines are positioned away from the perimeter, then coolant distribution may be improved, but response time to thermal events at battery edges increases
Solution Approach 1:
The thermal management system divides the battery pack into multiple zones with separate thermally-activated valves positioned at different locations including perimeter areas. Each valve independently responds to thermal events in its local zone, ensuring rapid response to thermal runaway at any specific location without requiring centralized control.
3Adaptability or versatility
If thermally activated material is used in the valves, then temperature threshold response is achieved, but valve mechanism complexity increases
Solution Approach 1:
The thermally-activated material in the valve utilizes phase transition (such as melting or expansion) at a predetermined temperature threshold to mechanically actuate the valve opening. This phase change provides a reliable, repeatable response mechanism that converts thermal energy directly into mechanical valve movement without complex control systems.
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 manages heat in battery packs by spraying coolant onto modules in excess of normal operating temperatures, maintaining efficiency and structural integrity without relying on functional temperature sensors, even in damaged systems.
Implementation Method 1
a thermally activated material disposed within the hollow body preventing fluid communication between the coolant line and the one or more battery modules when the temperature of the thermally activated material is below the temperature threshold
Implementation Method 2
The thermally activated material can be [(CH2)11C(O)NH]n
Implementation Method 3
heat transfer fluid is circulated within a battery pack to introduce or remove heat
Implementation Method 4
The at least one thermally activated valve can be configured to spray coolant onto one or more battery modules responsive to a temperature within the battery pack exceeding a temperature threshold
Data Source
AI summary
A battery pack thermal management system can include a battery pack including a plurality of battery modules encased within a battery case, a coolant line having an inlet and an outlet each penetrating a perimeter of the battery case and at least one thermally activated valve. The at least one thermally activated valve can be configured to spray coolant onto one or more battery modules responsive to a temperature within the battery pack exceeding a temperature threshold. The temperature threshold can be defined based on the temperature of a thermal event occurring within the battery pack which exceeds a normal operating temperature of the battery pack. The coolant line within the battery pack is biased towards the perimeter of the battery case. The battery pack can power a battery electric or hybrid electric vehicle.