Two-Phase Immersion Cooling With Pressure Waves for EV Heat Control
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Solution Overview
Problem
Existing cooling systems for electric vehicle components struggle to manage the increased power density and operating voltage, leading to significant heating issues that can affect performance and cause premature damage.
Innovation Solution
Implementing a two-phase cooling system with a variable volume member and pressure wave generators to manage phase changes and bubble formation, using a controller to adjust volumes and generate pressure waves to maintain optimal temperature ranges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If power density and operating voltage of battery systems are increased, then power delivery and charging capability are improved, but significant heating of battery cells, modules, packs and EV components occurs
Solution Approach 1:
The patent employs two-phase cooling systems where the cooling fluid transitions between liquid and vapor states to absorb and remove heat from high power density EV components. The phase change process enables efficient heat transfer at constant temperature, directly addressing the heating issue while maintaining high power operation
Solution Approach 2:
The system uses periodic pressure wave generation to maintain optimal bubble dynamics in the two-phase cooling process. Pressure waves are generated at specific frequencies and amplitudes to prevent bubble accumulation and ensure continuous heat transfer, enabling sustained high power density operation
2Power
If two-phase cooling systems are implemented, then cooling capacity is enhanced up to ten times that of single-phase systems, but system complexity increases with variable volume members and pressure wave generators
Solution Approach 1:
The patent incorporates a variable volume member that dynamically adjusts the cooling chamber volume in response to thermal load conditions. This dynamic adjustment optimizes the two-phase cooling process efficiency while managing the complexity through adaptive control rather than fixed design
Solution Approach 2:
The system employs feedback control mechanisms where temperature and pressure sensors monitor the cooling process, and the controller adjusts pressure wave generation and volume parameters accordingly. This feedback loop maintains optimal cooling performance while managing system complexity through intelligent control algorithms
3Reliability
If pressure waves are generated to manage bubble formation, then bubble accumulation is decreased and heat transfer is improved, but additional components and control mechanisms are required
Solution Approach 1:
The patent uses pressure wave generation (acoustic vibration) to manipulate bubble behavior in the cooling fluid. The mechanical vibration prevents bubble accumulation on heat transfer surfaces and promotes efficient phase change, directly improving heat transfer reliability through physical vibration rather than complex mechanical removal mechanisms
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
Enhances cooling capacity by up to ten times that of single-phase systems, effectively managing temperature fluctuations and preventing damage by maintaining the EV components within optimal operating ranges.
Implementation Method 1
Heat from operation of the electric vehicle component causes the cooling fluid to transition between a liquid state and a vapor state in the combined volume
Implementation Method 2
A condenser is arranged in the housing and is configured to cause the cooling fluid to transition from the vapor state back to the liquid state
Implementation Method 3
A pressure wave generator is in communication with the controller and is configured to selectively generate pressure waves in the cooling fluid to decrease bubbles accumulating on the electric vehicle component
Data Source
AI summary
A cooling system includes a housing configured to enclose an electric vehicle component immersed in cooling fluid and to define a first volume. A variable volume member defines a second volume that varies in response to a first signal. A combined volume is defined by the first volume and the second volume. Heat causes the cooling fluid to transition between a liquid state and a vapor state in the combined volume. A pressure sensor is configured to sense a pressure in the combined volume. A condenser is configured to cause the cooling fluid to transition from the vapor state back to the liquid state. A controller includes a volume adjustment module configured to generate the first signal to vary the second volume of the variable volume member to adjust the combined volume in response to the pressure and a first temperature of the electric vehicle component.