Direct cooling system integrating battery thermal management and ATS
By integrating battery thermal management with the ATS direct cooling system, the refrigerant is used to directly cool the battery and ATS, solving the electrical safety risks and space layout conflicts of liquid cooling solutions. This achieves safe, compact, and efficient thermal management, improving overall vehicle performance and range.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- VALEO THERMAL COMMERCIAL VEHICLES SYST (SUZHOU) CO LTD
- Filing Date
- 2026-01-07
- Publication Date
- 2026-04-21
AI Technical Summary
Existing liquid cooling solutions pose electrical safety risks and space layout conflicts in pure electric vehicles. Liquid leakage may lead to problems such as short circuits and corrosion. At the same time, additional heat dissipation arrangements will compress other core components, affecting the overall vehicle performance and range.
The system adopts a direct cooling system with integrated battery thermal management and ATS, which uses refrigerant to directly cool the battery and ATS, eliminating the need for water circulation. Through the integrated circulation channel of the compression module, condensation module, ATS module and battery thermal management module, combined with the control of electronic expansion valve and solenoid valve, the battery and ATS can be cooled independently or together.
It eliminates the safety risk of leakage, reduces the number of components and system size, lowers manufacturing costs, improves energy efficiency, and ensures the stable operation of the battery and ATS.
Smart Images
Figure CN121893722A_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of new energy vehicle technology, specifically to a direct cooling system that integrates battery thermal management and ATS. Background Technology
[0002] The three core components of a pure electric vehicle (battery, motor, and electronic control system) rely on precise thermal management for stable and reliable operation. Among them, the battery thermal management system and ATS (intelligent direct cooling system) are key components of thermal management, and liquid cooling (such as water cooling) is often used as the core heat dissipation method to achieve efficient cooling.
[0003] However, the current liquid cooling solution faces two major challenges in practical applications, which restrict the overall vehicle safety and performance:
[0004] First, there are significant electrical safety risks: liquid cooling systems rely on liquid circulation for heat exchange, but their pipes, interfaces, and other components have potential leakage hazards. Once a leak occurs, the liquid comes into contact with the electrical components of the three-electric system, which can easily cause short circuits, corrosion, and other problems, directly threatening the electrical safety of the entire vehicle.
[0005] Secondly, there are obvious conflicts in space layout: the interior space of pure electric vehicles is already compact, and the battery thermal management system and the heat dissipation components of ATS (such as cooling coils, heat exchangers, etc.) all require independent installation space. The additional heat dissipation arrangement will squeeze the installation space of other core components such as motors, electronic controls, and batteries, which may lead to unreasonable component layout and thus affect key indicators such as vehicle power performance and range. Summary of the Invention
[0006] To solve the above-mentioned technical problems, this application provides the following technical solution:
[0007] This application provides a direct cooling system integrating battery thermal management and ATS, comprising:
[0008] Compression module;
[0009] The condensing module includes a condenser with an inlet, an outlet, and intermediate inlets and outlets. The inlet is connected to the compression module, the intermediate inlets and outlets are connected to the ATS module, the outlet is connected to the cold inlet of the battery thermal management module via a cold pipe, and the heat outlet of the battery thermal management module is connected to the compression module via a heat pipe.
[0010] In one embodiment, a regenerator is also included, which is disposed on the cold pipe and the heat pipe.
[0011] In one embodiment, a first electronic expansion valve is provided on the cooling pipe, which is opened in a controlled manner when the battery thermal management module is cooled separately.
[0012] In one embodiment, a bypass is provided in parallel with the ATS module, and a solenoid valve is configured on the bypass. When the battery thermal management module is cooled separately, the solenoid valve is opened in a controlled manner.
[0013] In one embodiment, a branch channel is connected between the intermediate outlet of the condenser and the heat pipe, and a second electronic expansion valve is configured on the branch channel;
[0014] When the ATS module is cooled independently, the solenoid valve is closed in a controlled manner, and the second electronic expansion valve is opened in a controlled manner.
[0015] In one embodiment, when the battery thermal management module and the ATS module are cooled simultaneously, the solenoid valve is closed in a controlled manner, and the first electronic expansion valve and the second electronic expansion valve are opened in a controlled manner.
[0016] In one embodiment, the intermediate outlet of the condenser is connected to the inlet of the ATS module, and the intermediate inlet of the condenser is connected to the outlet of the ATS module.
[0017] In one embodiment, the battery thermal management module includes a battery cold plate, with cold pipes and heat pipes respectively connected to the battery cold plate.
[0018] In one embodiment, a high-pressure sampling module is provided on the cold pipe, and a low-pressure sampling module is provided on the hot pipe.
[0019] In one embodiment, the compression module, condensation module, ATS module and battery thermal management module are connected to form a refrigerant circulation channel, and the circulation channel is equipped with several temperature sensors for monitoring each area.
[0020] This application has at least the following beneficial effects:
[0021] The direct cooling system provided in this application integrates battery cooling and ATS cooling, directly cooling the battery and ATS with refrigerant. This eliminates the need for water circulation, not only preventing safety risks caused by leakage but also significantly reducing the number of components, the size of the battery and ATS direct cooling system, and manufacturing costs. Simultaneously, the elimination of intermediate heat exchange greatly improves energy efficiency. Attached Figure Description
[0022] Figure 1 This is a schematic diagram of a direct cooling system provided in an embodiment of this application.
[0023] Figure 2 This is a schematic diagram of the battery thermal management module operating independently in a direct cooling system according to an embodiment of this application.
[0024] Figure 3 This is a schematic diagram of the ATS module operating independently in a direct cooling system according to an embodiment of this application.
[0025] Figure 4 This is a schematic diagram showing the simultaneous operation of the battery thermal management module and the ATS module in a direct cooling system according to an embodiment of this application.
[0026] Figure 5 A simplified schematic diagram of a condenser provided in one embodiment of this application. Detailed Implementation
[0027] To make the above-mentioned objectives, features, and advantages of this application more apparent and understandable, the specific embodiments of this application are described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of this application. However, this application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this application. Therefore, this application is not limited to the specific embodiments disclosed below.
[0028] In the description of this application, it should be understood that if terms such as "length", "width", "thickness", "upper", "lower", "vertical", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc. appear, these terms indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.
[0029] Furthermore, where the terms "first," "second," and "third" appear, these terms are for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined with "first," "second," and "third" may explicitly or implicitly include at least one of those features. In the description of this application, where the term "multiple" appears, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.
[0030] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.
[0031] In this application, unless otherwise expressly specified and limited, the use of descriptions such as "above" or "below" the second feature indicates that the first and second features are in direct contact or indirect contact via an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. Similarly, "below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.
[0032] It should be noted that if an element is referred to as being "fixed to," "set on," or "contained on" another element, it can be directly on the other element or there may be an intervening element. If an element is considered to be "connected to" another element, it can be directly connected to the other element or there may be an intervening element. If so, the terms "vertical," "horizontal," "upper," "lower," "left," "right," and similar expressions used in this application are for illustrative purposes only and do not represent the only possible implementation.
[0033] The embodiments of this application are described in detail below with reference to the accompanying drawings.
[0034] Reference Figure 1 , 5 As shown, some embodiments of this application provide a direct cooling system integrating battery thermal management and an ATS (Automatic Temperature Regulator), including a compression module, a condensation module, an ATS module, and a battery thermal management module. These modules are connected to form a refrigerant circulation channel. The condensation module includes a condenser and a condenser fan. The condenser fan blows air towards the condenser, accelerating the heat exchange rate by increasing the gas flow rate. In this solution, the condenser has an inlet, an outlet, and intermediate inlet and outlet, allowing the refrigerant to flow out from the intermediate outlet and return to the condenser from the intermediate inlet during its flow through the condenser. Specifically, the condenser inlet is connected to the compression module, and the intermediate inlet and outlet of the condenser are connected to the ATS module. That is, the intermediate outlet of the condenser is connected to the inlet of the ATS module, and the intermediate inlet of the condenser is connected to the outlet of the ATS module. This allows the cooled refrigerant flowing out from the intermediate outlet in the condenser to cool the ATS module, and the refrigerant absorbs heat in the ATS module before returning to the condenser to dissipate heat again. The condenser outlet is connected to the cold inlet of the battery thermal management module via a cold pipe, and the heat outlet of the battery thermal management module is connected to the compression module via a heat pipe. After absorbing heat, the refrigerant is cooled again in the condenser and then enters the battery thermal management module through the outlet to further cool the battery.
[0035] During operation, the ATS module and the battery thermal management module operate at different temperatures. The ATS module can operate below 65°C, while the battery operates at 20°C. Therefore, the refrigerant at different locations on the condenser is used to cool the ATS and battery separately. The suitable operating temperature range for the ATS is relatively high. In this solution, the refrigerant cooled by the condenser is used directly to cool the ATS. The vaporized refrigerant returns to the condenser, undergoes cooling and liquefaction, and is then discharged from the condenser to supply cooling for the battery.
[0036] In this design, the battery and ATS share the same condenser module for cooling using refrigerant. Direct refrigerant cooling of both the battery and ATS eliminates the need for water circulation, thus preventing safety risks associated with leaks, significantly reducing the number of components, the size of the direct cooling system for the battery and ATS, and lowering manufacturing costs. Furthermore, because the ATS operates at high temperatures, the refrigerant cooled by the condenser directly cools the ATS, achieving the effect of a dry cooler without consuming additional power from the compression module, resulting in high energy efficiency.
[0037] The battery thermal management module includes a battery cold plate, with cold pipes and heat pipes connected to it. The battery cold plate plays a crucial role in the electric vehicle's battery thermal management system. Its working mechanism involves circulating the refrigerant through channels on the cold plate, efficiently transferring the heat generated during battery operation to the refrigerant. Simultaneously, while the refrigerant absorbs heat and is quickly removed from the cold plate, supercooled refrigerant is replenished to continue absorbing heat, ensuring the battery operates within a normal temperature range.
[0038] Furthermore, the direct cooling system also includes a regenerator, which is located on the cold and heat pipes. On one hand, the regenerator can reheat the refrigerant after it has been cooled by the battery and send the high-temperature refrigerant into the compression module. On the other hand, the regenerator can also cool the refrigerant at the condenser outlet, increasing the subcooling of the refrigerant entering the battery thermal management system module. The regenerator, also known as a gas-liquid heat exchanger, uses refrigerant vapor from the thermal management system module to cool the high-pressure liquid before it enters the module. The regenerator is a heat exchange device that subcools the refrigerant liquid and superheats the vapor.
[0039] During use, it was found that to ensure the uniformity of the refrigerant's cooling effect on the battery, the refrigerant at the battery thermal management module outlet needs to be in a slightly liquid state. If the slightly liquid refrigerant enters the compression module, it can easily cause liquid slugging. To prevent liquid refrigerant from entering the compression module, one approach is to either separate the slightly liquid refrigerant from its gas-liquid state or heat it. However, separating the slightly liquid refrigerant from its gas-liquid state is more likely to cause refrigerant loss, reducing the amount of refrigerant circulating in the direct cooling system and requiring intermittent refrigerant replenishment. Heating the slightly liquid refrigerant, on the other hand, can ensure the amount of refrigerant circulating in the direct cooling system. In this solution, a regenerator is installed on the direct cooling system, which not only heats the slightly liquid refrigerant but also increases the subcooling of the refrigerant entering the battery thermal management system, further improving energy efficiency. The regenerator can also be a semiconductor refrigeration chip. When the semiconductor refrigeration chip is energized, it can form a hot end and a cold end. The hot end can heat the refrigerant in a slightly liquid state, and the cold end can increase the cooling capacity of the refrigerant entering the battery thermal management system.
[0040] In some embodiments of this application, a first electronic expansion valve is configured on the cooling pipe. When cooling is supplied to the battery thermal management module alone and / or to both the battery thermal management module and the ATS module simultaneously, the first electronic expansion valve is opened in a controlled manner. The flow rate of refrigerant entering the battery thermal management module is controlled by the first electronic expansion valve.
[0041] Furthermore, a bypass passage is provided in parallel with the ATS module, and a solenoid valve is configured on the bypass passage. When the battery thermal management module is cooled independently, the solenoid valve is opened in a controlled manner. To prevent a drop in fluid pressure caused by refrigerant passing through the ATS module when the battery thermal management module is running independently, this solution incorporates a bypass passage. When the battery thermal management module is running independently, the solenoid valve on the bypass passage is opened in a controlled manner, creating a bypass passage through which the refrigerant returns to the condenser, thus maintaining fluid pressure.
[0042] Furthermore, a branch channel connects the condenser's intermediate outlet to the heat pipe, and a second electronic expansion valve is installed on the branch channel. Through the branch channel, the refrigerant discharged from the ATS module can directly enter the compression module. Specifically, when cooling the ATS module alone and / or simultaneously cooling the battery thermal management module and the ATS module, the second electronic expansion valve is opened in a controlled manner. The second electronic expansion valve controls the flow rate of refrigerant entering the ATS module. For example, the refrigerant discharged from the condenser's intermediate outlet is divided into two paths: one path flows back to the compression module through the branch channel, and the other path flows into the ATS module and back into the condenser. Because the second electronic expansion valve is installed on the branch channel, when the amount of refrigerant discharged from the condenser's intermediate outlet is a fixed value, adjusting the second electronic expansion valve can control the amount of refrigerant entering the branch channel, thereby controlling the amount of refrigerant flowing into the ATS module, and thus controlling the flow rate of refrigerant entering the ATS module.
[0043] In this embodiment, the integrated battery thermal management and ATS direct cooling system can control the battery thermal management module and the ATS module to operate independently or simultaneously, as needed. Specifically:
[0044] refer to Figure 2 As shown, when the battery thermal management module is cooled independently, the second electronic expansion valve is closed in a controlled manner, while the first electronic expansion valve and the solenoid valve are opened in a controlled manner. After being discharged from the compressor module outlet, the refrigerant enters the condenser, is discharged from the middle outlet of the condenser, returns to the condenser module via a bypass, is discharged from the outlet of the condenser module, enters the battery thermal management module, and finally flows back to the compressor module after being cooled in the battery thermal management module.
[0045] refer to Figure 3 As shown, when the ATS module is cooled independently, the first electronic expansion valve and solenoid valve are closed in a controlled manner, while the second electronic expansion valve is opened in a controlled manner. After being discharged from the compressor module outlet, the refrigerant enters the condenser for cooling. The cooled refrigerant then exits from the condenser's central outlet and enters the ATS module, where it vaporizes after cooling the ATS. After being intercepted by the second electronic expansion valve, it returns to the compressor. The second electronic expansion valve controls the refrigerant circulation rate within this direct-cooling system, ensuring that all refrigerant entering the ATS is completely vaporized.
[0046] refer to Figure 4 As shown, when both the battery thermal management module and the ATS module are cooled simultaneously, the solenoid valve is closed in a controlled manner, while the first and second electronic expansion valves are opened in a controlled manner. The high-temperature, high-pressure refrigerant discharged from the compressor is cooled by the condenser and then discharged from the condenser's central outlet into the ATS to cool it. After absorbing heat, the refrigerant re-enters the condenser for further cooling and then passes through the first electronic expansion valve for throttling before cooling the battery.
[0047] In this cycle, the first and second electronic expansion valves work together to control the refrigerant flow into the battery side, balancing the different refrigerant flow requirements for cooling the ATS and the battery side. Simultaneously, the gaseous refrigerant discharged from the line containing the second electronic expansion valve mixes with the gaseous refrigerant discharged from the battery side. The interaction between the first and second electronic expansion valves also allows for control of the compressor's suction superheat.
[0048] In some embodiments of this application, the integrated battery thermal management and ATS direct cooling system further includes a memory and a processor. The memory stores program instructions for performing the above-described control methods, and the processor executes the program instructions stored in the memory to achieve cooling of the battery and / or the ATS.
[0049] A processor can be a single-core processor (CPU) or a multi-core processor (CPU). The controller here can refer to one or more devices, circuits, and / or processing cores used to process data (such as computer program instructions).
[0050] The memory can be read-only memory (ROM) or other types of static storage devices capable of storing static information and instructions, random access memory (RAM) or other types of dynamic storage devices capable of storing information and instructions, or electrically erasable programmable read-only memory (EEPROM), compact disc read-only memory (CD-ROM) or other optical disc storage, optical disc storage (including compressed discs, laser discs, optical discs, universal optical discs, Blu-ray discs, etc.), magnetic disk storage media or other magnetic storage devices, or any other medium capable of carrying or storing desired program code in the form of instructions or data structures and accessible by a computer, but not limited to these. The memory can exist independently or it can be integrated onto the processor.
[0051] In this design, a high-pressure sampling module is installed on the cold pipe, and a low-pressure sampling module is installed on the hot pipe. Several temperature sensors are installed on the circulation channel to monitor each area. The first electronic expansion valve, solenoid valve, and second electronic expansion valve are opened and closed under control. Specifically, the processor controls the opening and closing of the first electronic expansion valve, solenoid valve, and second electronic expansion valve according to requirements. After the first or second electronic expansion valve is opened, based on the data collected by the high-pressure sampling module, the low-pressure sampling module, and / or the data collected by the temperature sensors, the processor can also adjust the refrigerant flow rate through the first or second electronic expansion valve, thereby achieving processor-controlled operation of the first electronic expansion valve, solenoid valve, and second electronic expansion valve.
[0052] Those skilled in the art will understand that embodiments of this application can be provided as methods, systems, or computer program products. Therefore, this application can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, this application can take the form of a computer program product embodied on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.
[0053] This application is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of this application. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart... Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.
[0054] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.
[0055] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.
[0056] The above embodiments are used to further illustrate this application, but do not limit this application to these specific implementations. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this application should be understood as falling within the protection scope of this application.
Claims
1. A direct cooling system integrating battery thermal management and ATS, characterized in that, include: Compression module; The condensing module includes a condenser with an inlet, an outlet, and intermediate inlets and outlets. The inlet is connected to the compression module, and the intermediate inlets and outlets are connected to an ATS module. The outlet is connected to the cold inlet of the battery thermal management module via a cold pipe, and the heat outlet of the battery thermal management module is connected to the compression module via a heat pipe.
2. The direct cooling system according to claim 1, characterized in that, It also includes a regenerator, which is disposed on the cold pipe and the heat pipe.
3. The direct cooling system according to claim 1 or 2, characterized in that, The cooling pipe is equipped with a first electronic expansion valve, which is opened in a controlled manner when the battery thermal management module is cooled separately.
4. The direct cooling system according to claim 3, characterized in that, A bypass passage is provided in parallel with the ATS module, and a solenoid valve is configured on the bypass passage. When the battery thermal management module is cooled separately, the solenoid valve is opened in a controlled manner.
5. The direct cooling system according to claim 4, characterized in that, A branch channel is connected between the middle outlet of the condenser and the heat pipe, and a second electronic expansion valve is configured on the branch channel; When the ATS module is cooled independently, the solenoid valve is closed in a controlled manner, and the second electronic expansion valve is opened in a controlled manner.
6. The direct cooling system according to claim 5, characterized in that, When the battery thermal management module and the ATS module are cooled simultaneously, the solenoid valve is closed in a controlled manner, and the first electronic expansion valve and the second electronic expansion valve are opened in a controlled manner.
7. The direct cooling system according to claim 1, characterized in that, The intermediate outlet of the condenser is connected to the inlet of the ATS module, and the intermediate inlet of the condenser is connected to the outlet of the ATS module.
8. The direct cooling system according to claim 1 or 2, characterized in that, The battery thermal management module includes a battery cold plate, and the cold pipe and the heat pipe are respectively connected to the battery cold plate.
9. The direct cooling system according to claim 8, characterized in that, The cold pipe is equipped with a high-pressure sampling module, and the hot pipe is equipped with a low-pressure sampling module.
10. The direct cooling system according to claim 1 or 2, characterized in that, The compression module, the condensation module, the ATS module, and the battery thermal management module are connected to form a refrigerant circulation channel, and the circulation channel is equipped with several temperature sensors for monitoring each area.