Temperature Dependent Optimized Cooling System for EV Battery Pack and a Method Thereof

Abstract

This invention presents an advanced thermal management system for battery packs, enhancing efficiency and safety through a novel approach to cooling. Central to the system is an innovative coolant structure that encases individual battery cells or groups of cells, maximizing surface contact and significantly improving heat transfer. Coupled with this is a dynamic, motor-controlled coolant distribution mechanism, which adjusts coolant flow in real-time based on temperature data from embedded sensors. A sophisticated algorithm processes this data to regulate coolant distribution, ensuring uniform temperature across the battery pack and preventing overheating. The system's safety protocols include automatic shutdown if critical temperature thresholds are exceeded, minimizing the risk of thermal runaway. Additionally, a feedback loop mechanism allows continuous learning and optimization of cooling strategies. This integrated solution not only enhances thermal management but also extends battery life, improves performance, and ensures higher safety standards, marking a significant advancement in battery thermal management technology

Specification

Description:FIELD OF INVENTION
[001] Electric Vehicle Technology.
BACKGROUND AND PRIOR ART
[002] A battery pack is a sophisticated assembly designed to efficiently store and deliver electrical power. It integrates numerous individual battery cells into one cohesive unit to achieve specific voltage and capacity goals. Central to its construction are several essential components. The cells, which serve as the primary energy storage elements, can be made from various materials, each offering distinct advantages in energy density, lifespan, and safety. Alongside these cells, the Battery Management System (BMS) plays a crucial role in monitoring the battery's performance, controlling charge cycles, and ensuring safety by preventing issues like overcharging and overheating. The battery's packaging includes an enclosure and structural elements that not only protect the internal components but also support thermal management. The cooling system, which might use passive techniques such as insulation or more active methods like air or liquid cooling, is vital for managing the heat produced during use. Together, the careful design and integration of these elements are essential for maximizing the battery pack's efficiency, safety, and durability across various applications, from consumer electronics to high-end energy storage solutions.
[003] The design of a battery pack is essential for maximizing performance, ensuring safety, and prolonging its lifespan. It influences efficiency by reducing internal resistance and improving thermal management, which aids in effective energy utilization. A well-crafted battery pack features safeguards against risks such as thermal runaway and provides reliability through advanced Battery Management Systems (BMS) and protective housings. It also enhances cost-efficiency by optimizing material usage and minimizing maintenance requirements, while addressing environmental concerns through the use of recyclable materials and sustainable practices. Thoughtfully designed battery pack ensures smooth integration with other systems, improving user experience by accommodating specific application requirements and constraints.
[004] Battery packs generate heat during operation, making effective cooling essential for optimal performance, safety, and longevity. Cooling systems are typically categorized into passive and active methods. Passive cooling involves thermal insulation, which uses materials with low thermal conductivity to slow heat transfer and prevent overheating, and heat sinks, which absorb and dissipate heat through natural convection or radiation. Active cooling, on the other hand, includes air cooling, where fans circulate air around the battery pack to enhance heat dissipation-a simple and cost-effective approach but less suitable for high-power applications. More advanced, liquid cooling systems use a coolant, often a water or glycol mixture, circulated through channels or pipes in contact with the battery pack. This method offers more efficient heat removal and is commonly used in high-performance or electric vehicle battery packs. Current cooling technologies for battery packs encompass various effective methods. Air Cooling relies on fans and ventilation systems to circulate air and dissipate heat, making it suitable for consumer electronics and smaller battery packs with low to moderate thermal loads, though less effective for high-power applications. Liquid Cooling is commonly used in electric vehicles and high-performance scenarios, featuring cold plates with embedded channels for coolant circulation, coolant pumps for consistent temperature regulation, and radiators to expel heat to the environment. Phase Change Materials (PCMs) help stabilize temperatures by absorbing and releasing thermal energy during phase changes, often in conjunction with other cooling strategies to improve thermal management. Thermoelectric Coolers (TECs) utilize the Peltier effect to move heat away from the battery and are often used alongside other cooling methods for precise temperature control. Although air and liquid cooling are the main techniques, liquid cooling is favored for high-power needs, with emerging technologies like PCMs and TECs enhancing overall cooling efficiency.
[005] Liquid cooling systems effectively manage the thermal demands of high-capacity battery packs, tackling issues such as heat generated from internal resistance, high discharge currents, and charge cycles. They excel in heat dissipation thanks to the superior thermal conductivity of liquids, ensure even temperature distribution to prevent hotspots, and offer a more compact design compared to air cooling systems. These systems are also adaptable to various battery sizes and power levels. Key factors include selecting appropriate coolants, designing efficient cooling architecture, integrating seamlessly with the battery pack, and ensuring safety and reliability through comprehensive testing.
[006] Metal plates with integrated cooling channels represent a notable advancement in thermal management by leveraging the excellent heat transfer properties of metals such as aluminum and copper. This design facilitates effective and uniform cooling across the entire battery pack, mitigating hotspots and thereby boosting both performance and safety. Their compact and adaptable design addresses various application needs, accommodating constraints related to size and weight. Critical design factors include optimizing channel configurations, choosing appropriate metals and coolants, and ensuring robust manufacturing and integration. As battery technologies advance, this cooling method is expected to be crucial for tackling thermal issues, enhancing performance, and prolonging the lifespan of energy storage systems.
SUMMARY OF THE INVENTION
[007] The invention revolutionizes battery cooling through an advanced thermal management system designed to optimize the efficiency and safety of battery packs. At its core, the system features a pioneering coolant structure that encases each individual battery cell or groups of cells within the pack. This novel structure is meticulously crafted to maximize the surface area in contact with the coolant, significantly improving heat transfer and dissipation. The expanded contact area ensures that heat generated by the battery cells is quickly and effectively drawn away by the coolant, preventing localized overheating and maintaining uniform temperature distribution across the pack.
[008] In conjunction with this innovative coolant structure, the system incorporates a dynamic, motor-controlled coolant distribution mechanism. This mechanism is responsive to real-time temperature data collected from an array of sensors embedded throughout the battery pack. These sensors continuously monitor the temperature of various cells and regions within the pack, providing real-time feedback to the system's central control unit. The data is processed by a sophisticated algorithm designed to manage coolant flow precisely.
[009] The algorithm's primary function is to regulate the distribution of coolant based on the temperature readings it receives. It adjusts the flow rate and direction of the coolant dynamically, ensuring that hotter areas receive increased cooling and that cooler areas are not over-cooled. This adaptive cooling strategy is crucial for maintaining the battery pack within its optimal operating temperature range, enhancing overall performance and efficiency.
[010] Safety is a critical aspect of the system's design. The algorithm includes a built-in safety protocol that monitors for any temperature deviations beyond predefined critical thresholds. If the temperature at any point in the battery pack exceeds these safety limits, the algorithm immediately activates a cutoff mechanism. This safety cut-off stops the battery system's operation to prevent potential overheating, reducing the risk of thermal runaway, damage, or safety hazards.
[011] Furthermore, the system is equipped with a feedback loop mechanism that enables continuous learning and adaptation. As the algorithm gathers more data on temperature trends and performance, it refines its cooling strategies to improve efficiency over time. This ongoing optimization ensures that the system remains effective under varying operational conditions and usage patterns.
[012] Overall, this integrated cooling solution not only enhances thermal management but also contributes to extended battery life, improved performance, and a higher level of safety. By combining a novel coolant structure with dynamic distribution control and real-time adaptive algorithms, the invention represents a significant advancement in battery thermal management technology.
BRIEF DESCRIPTIONS OF DRAWINGS:
[013] Figure 1.(a), shows the orthographic view of cell arrangement of configuration 2p8s with coolant plates arranged in curved manner around the cells, where in 75% of the 2 cells surface area comes in contact with the coolant plate which is designed to have one loop for 2 cells. The coolant plate in pink proposition also depicts the baffles present which helps in even distribution of the coolant flow in various regions. Figure 1. (b) and (c) shows the various other forms of projections of the similar configuration.
DETAILED DESCRIPTION OF THE INVENTION
[014] This invention addresses the critical need for effective thermal management in battery packs, particularly for applications in electric vehicles and high-performance energy storage systems. The advanced thermal management system significantly enhances the efficiency, safety, and longevity of battery packs through a novel coolant structure, dynamic coolant distribution mechanism, sophisticated algorithm, and continuous optimization feedback loop.
[015] At the heart of the invention is a pioneering coolant structure designed to maximize heat transfer efficiency. This structure encases each individual battery cell or groups of cells within the pack, substantially increasing the surface area in contact with the coolant. The design ensures that a large portion of each cell's surface area is exposed to the coolant, facilitating rapid and effective heat dissipation. The structure's key features include:
[016] Curved Coolant Plates: These plates wrap around the cells, ensuring that at least 75% of the cell surface area is in contact with the coolant. This design minimizes thermal resistance and maximizes heat transfer.
[017] Baffles: Incorporated within the coolant plates, these baffles promote even distribution of coolant flow, preventing hotspots and ensuring uniform cooling across all cells.
[018] To complement the innovative coolant structure, the system includes a dynamic, motor-controlled coolant distribution mechanism. This mechanism is designed to respond in real-time to temperature variations within the battery pack, ensuring optimal cooling efficiency. Key components and functions include:
[019] Temperature Sensors: An array of sensors is embedded throughout the battery pack, continuously monitoring the temperature of individual cells and regions.
[020] Central Control Unit: This unit receives temperature data from the sensors and processes it using a sophisticated algorithm.
[021] Motor-Controlled Coolant Flow: Based on the processed data, the control unit dynamically adjusts the flow rate and direction of the coolant. This ensures that hotter areas receive more cooling, while cooler areas are not over-cooled.
[022] The algorithm is a critical component of the thermal management system, responsible for precise regulation of the coolant distribution. Its primary functions include:
[023] Real-Time Data Processing: Continuously processes temperature data from the sensors.
[024] Adaptive Cooling Strategy: Adjusts coolant flow dynamically to maintain uniform temperature distribution and prevent overheating.
[025] Safety Protocols: Includes predefined critical temperature thresholds. If any sensor detects a temperature beyond these limits, the algorithm triggers an immediate shutdown of the battery system to prevent thermal runaway and other safety hazards.
[026] The system incorporates a feedback loop mechanism that enables continuous learning and adaptation. This feature ensures ongoing optimization of the cooling strategies based on real-world operating conditions and usage patterns. The feedback loop works as follows:
[027] Data Collection: Gathers extensive temperature and performance data over time.
[028] Algorithm Refinement: Uses this data to refine and improve the cooling strategies, enhancing the system's efficiency and effectiveness.
[029] Adaptability: Ensures the system remains effective under varying operational conditions, extending battery life and improving overall performance. , C , Claims:[030] 1. A thermal management system for battery packs comprising an innovative coolant structure that encases individual battery cells or groups of cells, designed to maximize the surface area in contact with the coolant, thereby significantly improving heat transfer and dissipation.
[031] 2. The thermal management system of claim 1, wherein the coolant structure includes curved coolant plates that wrap around the battery cells, ensuring that at least 75% of the cell surface area is in contact with the coolant.
[032] 3. The thermal management system of claim 1, wherein the coolant plates include integrated baffles to promote even distribution of the coolant flow and prevent hotspots within the battery pack.
[033] 4. A thermal management system comprising a dynamic, motor-controlled coolant distribution mechanism responsive to real-time temperature data collected from sensors embedded throughout the battery pack.
[034] 5. The thermal management system of claim 4, wherein the embedded temperature sensors continuously monitor the temperature of individual cells and regions within the battery pack, providing real-time feedback to the central control unit.
[035] 6. The thermal management system of claim 4, wherein the central control unit processes the temperature data using a sophisticated algorithm designed to regulate the distribution of coolant, adjusting flow rate and direction dynamically based on temperature readings.
[036] 7. The thermal management system of claim 6, wherein the algorithm employs an adaptive cooling strategy to maintain uniform temperature distribution across the battery pack, enhancing overall performance and efficiency.
[037] 8. The thermal management system of claim 6, wherein the algorithm includes safety protocols that monitor for temperature deviations beyond predefined critical thresholds and activate a cutoff mechanism to stop the battery system's operation in case of potential overheating.
[038] 9. A thermal management system equipped with a feedback loop mechanism that enables continuous learning and adaptation, refining cooling strategies over time based on collected temperature trends and performance data.
[039] 10. The thermal management system of claim 1, wherein the integrated cooling solution not only enhances thermal management but also contributes to extended battery life, improved performance, and a higher level of safety by preventing localized overheating and maintaining uniform temperature distribution

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