Battery Bypass Coolant Loops for EV Thermal Balance
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Solution Overview
Problem
Electrified vehicle thermal management systems face challenges in maintaining battery and power electronics components within optimal temperature ranges, as conventional systems struggle to efficiently manage heat rejection and temperature fluctuations, potentially degrading battery performance and longevity.
Innovation Solution
A thermal management system incorporating a coolant subsystem with an air cooler loop, battery bypass loop, and a control unit that directs coolant flow based on temperature thresholds, using sensors to monitor coolant and battery cell temperatures, and includes a radiator and pump for efficient heat management, allowing or preventing coolant flow to the traction battery pack or bypass loop to maintain optimal temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If coolant flow is directed through the water charge air cooler to reject heat, then heat rejection efficiency is improved, but battery temperature control deteriorates due to excessive cooling
Solution Approach 1:
The coolant flow path is segmented into multiple independent loops: a first coolant loop for the water charge air cooler and a second coolant loop for the battery pack. This segmentation allows each loop to be controlled independently, enabling the system to reject heat efficiently through the air cooler while simultaneously maintaining precise temperature control for the battery pack through separate flow management.
Solution Approach 2:
The system dynamically adjusts coolant flow distribution between the two loops based on real-time thermal conditions. The control system monitors temperatures and heat rejection requirements, then dynamically modulates valve positions and pump operations to optimize both heat rejection efficiency and battery temperature control under varying operating conditions.
2Temperature
If a traditional chiller system is used to manage battery temperature, then temperature control precision is improved, but system cost increases
Solution Approach 1:
The coolant subsystem is designed with multi-functionality to serve both heat rejection and battery temperature control purposes through a unified system architecture. By sharing common components (pumps, valves, coolant reservoir) between the air cooler loop and battery loop, the system achieves precise temperature control without requiring a separate chiller system, thereby reducing overall system cost and complexity.
Solution Approach 2:
The system utilizes the heat rejection capability of the water charge air cooler to indirectly support battery temperature management. By strategically directing coolant flow between the two loops, the system leverages the existing air cooler infrastructure to provide cooling capacity for the battery pack, eliminating the need for additional active cooling equipment and reducing system costs.
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
The system effectively maintains battery and power electronics components within desired temperature ranges, improving performance and extending battery life by dynamically managing heat rejection and preventing thermal degradation, while avoiding the costs associated with traditional chiller systems.
Implementation Method 1
a control unit configured to control a position of the valve based on an amount of heat rejection into the coolant from the water charge air cooler
Implementation Method 2
the coolant subsystem includes a radiator and a pump
Data Source
AI summary
This disclosure details thermal management systems for thermally managing electrified vehicle components. An exemplary thermal management system may be configured to direct a coolant through a battery bypass loop that bypasses a traction battery pack based on an amount of heat rejection into the coolant from a water charge air cooler.