Battery Thermal Management Bypass Valve for Coolant Temperature Control
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Solution Overview
Problem
Conventional thermal management systems in electric vehicles experience rapid coolant temperature swings and inefficient cooling capacity utilization due to oversizing of heat exchangers for maximum thermal loading conditions, leading to excessive heat rejection and reduced flexibility in regulating thermal dissipation.
Innovation Solution
A thermal management system with a by-pass valve that regulates coolant flow through a heat exchanger, allowing a portion of the coolant to bypass the heat exchanger and recombine with the cooled portion, enabling continuous adjustment of thermal dissipation based on preset temperature ranges for the battery pack and passenger cabin, and optimizing refrigeration system output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the heat exchanger is sized for maximum thermal loading conditions, then sufficient cooling capacity is ensured under maximum thermal loading, but rapid coolant temperature swings and large swings in cooling capacity occur under normal operating conditions
Solution Approach 1:
The patent applies dynamics by making the heat exchanger configuration adjustable through a by-pass valve that can dynamically change the coolant flow path. The valve allows the system to transition between different operational states: full heat exchanger engagement for maximum cooling, partial bypass for reduced cooling, and complete bypass when cooling is not needed. This dynamic adjustment prevents temperature swings by matching the cooling capacity to the actual thermal load conditions.
Solution Approach 2:
The patent changes the flow rate parameter of coolant through the heat exchanger by introducing a by-pass valve. By adjusting the valve position, the system varies the coolant flow rate through the heat exchanger from maximum (when valve is closed) to zero (when valve is fully open). This parameter change allows the system to adapt to different thermal loading conditions and maintain stable coolant temperature by preventing over-cooling.
2Power
If the heat exchanger is sized for maximum thermal loading conditions, then adequate cooling is provided during peak demand, but cooling capacity is excessive and inefficient during normal operation
Solution Approach 1:
The patent applies partial action by allowing the coolant to partially bypass the heat exchanger based on actual cooling needs. Instead of always using the full cooling capacity designed for maximum thermal loading, the system uses only the necessary portion of cooling capacity during normal operation. The by-pass valve enables this partial engagement of the heat exchanger, preventing energy waste from excessive cooling while maintaining adequate cooling capacity when needed.
3Adaptability or versatility
If the coolant pump speed is regulated to control coolant flow through the heat exchanger, then cooling capacity can be adjusted, but system complexity increases
Solution Approach 1:
The patent extracts the flow control function from the coolant pump and places it in a dedicated by-pass valve positioned in parallel with the heat exchanger. This separation allows the pump to operate at constant speed while the valve handles the complexity of flow regulation. The valve provides simple on/off or proportional control of the bypass flow, which is mechanically simpler than variable speed pump control and reduces overall system complexity while maintaining adaptability.
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 solution maintains a stable coolant temperature within desired ranges, optimizing thermal dissipation and reducing cooling capacity swings, thereby improving the efficiency and flexibility of thermal management in electric vehicles.
Implementation Method 1
a heat exchanger, a refrigeration system thermally coupled to the heat exchanger, and a coolant loop thermally coupled to the vehicle's battery pack and thermally coupled to the heat exchanger
Implementation Method 2
a by-pass valve that regulates coolant flow through the heat exchanger, where the by-pass valve is coupled to the coolant loop between the heat exchanger inlet and outlet ports such that the by-pass valve operates in parallel with the heat exchanger
Data Source
AI summary
A method of regulating thermal dissipation from a vehicle battery pack is provided in which a by-pass valve is used to control the amount of battery pack coolant either passing through, or by-passing, a heat exchanger, where the coolant passing through the heat exchanger is cooled by a refrigeration system. The vehicle's HVAC system is controlled to insure that HVAC operation does not compromise maintaining the battery pack within an acceptable range of temperatures.