Alternating Flow Channels in Battery Cooling Plate for Hybrid Vehicles
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Solution Overview
Problem
Existing refrigerant circuits in hybrid electric vehicles cannot operate the battery cooling plate independently of the air conditioning evaporator, leading to limitations in battery cooling during cold weather, as the battery cooling plate must always be in the wet vapor region to prevent liquid hammer damage to the compressor.
Innovation Solution
The refrigerant plate is designed with alternating pre-flow and return-flow channels to ensure even temperature distribution, allowing it to operate directly in front of the compressor with gaseous refrigerant, decoupling battery cooling from air conditioning and enabling independent operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the battery cooling plate is connected in series with the air conditioning evaporator to prevent liquid hammer, then the compressor is protected from damage, but the battery cooling cannot operate independently during cold weather
Solution Approach 1:
The refrigerant circuit is segmented into two independent parallel paths: one through the battery cooling plate and another through the air conditioning evaporator. This allows the battery cooling system to operate independently by opening the first three-way valve, directing refrigerant flow solely through the battery cooling plate without requiring the air conditioning evaporator to be active.
Solution Approach 2:
The system uses dynamically controllable three-way valves to switch between different operational modes. The first three-way valve can dynamically redirect refrigerant flow to bypass the air conditioning evaporator when battery cooling is needed independently, while the second three-way valve manages the refrigerant flow distribution between parallel paths, enabling adaptive operation based on thermal conditions.
2Manufacturing precision
If the battery cooling plate is operated in the wet vapor region to ensure uniform cooling, then all cells are cooled evenly, but liquid refrigerant reaches the compressor causing liquid hammer
Solution Approach 1:
The harmful liquid refrigerant is extracted and removed from the flow path before it can reach the compressor. The second three-way valve is positioned to intercept and redirect the refrigerant flow, separating the liquid-containing stream from the compressor inlet and directing it through an alternative path that prevents liquid hammer while maintaining the wet vapor region operation for uniform cooling.
Solution Approach 2:
The second three-way valve acts as an intermediary device between the battery cooling plate outlet and the compressor inlet. It mediates the refrigerant flow by detecting or predicting liquid presence and actively redirecting the flow to prevent liquid hammer, allowing the system to maintain optimal wet vapor region operation without exposing the compressor to liquid damage.
3Reliability
If the air conditioning evaporator is operated to re-evaporate liquid refrigerant, then liquid hammer is prevented, but the battery cooling plate cannot operate alone without it
Solution Approach 1:
The refrigerant circuit is divided into functionally independent segments with dedicated flow control. The battery cooling plate has its own independent flow path controlled by the first three-way valve, eliminating the requirement for the air conditioning evaporator to be active. The second three-way valve provides an additional safety segment that can prevent liquid hammer through alternative routing without requiring evaporator operation.
Solution Approach 2:
The system changes the operational parameters by using electronically controllable three-way valves that can rapidly switch between different flow configurations. This allows dynamic adjustment of refrigerant flow paths based on operational requirements, enabling the battery cooling plate to operate independently by changing valve positions rather than relying on fixed series connection with the air conditioning evaporator.
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
This design maintains a uniform temperature gradient on the battery cooling plate, preventing overheating and allowing the battery cooling system to function independently, even in cold conditions, by ensuring the refrigerant is gaseous at the compressor inlet, thus preventing liquid hammer and enabling efficient battery cooling.
Implementation Method 1
The device is designed to receive a fluid, in particular a refrigerant, in at least partially liquid form and to deliver the fluid, in particular a refrigerant, in gaseous form
Implementation Method 2
a heat sink which has a plurality of pre-flow flows and a plurality of return flow flows
Implementation Method 3
the forward and reverse flows lie directly next to one another... makes it possible to achieve a temperature distribution that is as uniform as possible within the heat sink
Implementation Method 4
A compressor can thus be connected downstream of the device without the risk of the compressor being damaged by liquid hammer
Data Source
AI summary
The present invention relates to a device for cooling a heat source of a motor vehicle, comprising a heat sink (220) having several upstream flow channels (222) and several downstream flow channels (224). At least a plurality of the upstream flow channels (222) and downstream flow channels (224) are arranged alternately side by side in the heat sink.