Vehicle Battery Thermal Loop Using Cascade Refrigeration Heating
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Solution Overview
Problem
Existing vehicle thermal management systems for electric vehicles rely on expensive electric heaters to maintain battery temperature, leading to high power consumption and reduced all-electric range, especially in cold weather.
Innovation Solution
A vehicle thermal management system that eliminates the electric heater by using a cascade refrigeration cycle with two refrigeration loops and a battery chiller to efficiently heat and cool the battery coolant, allowing the battery to maintain optimal temperature without direct electric heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If an electric heater is used to heat the battery-side coolant, then the battery temperature can be maintained at a predetermined temperature, but the power consumption increases and electric energy is wasted
Solution Approach 1:
The patent introduces a refrigerant as an intermediary substance to transfer heat from the ambient environment to the battery-side coolant. The refrigerant circulates through a refrigeration cycle system, absorbing heat from the environment and releasing it to the battery coolant, thereby eliminating the need for direct electric heating while maintaining battery temperature.
Solution Approach 2:
The patent replaces the electric heating system with a refrigeration-based thermal management system. Instead of using electrical energy to directly heat the battery, the system uses a refrigeration cycle with compressors, condensers, and evaporators to transfer thermal energy mechanically, significantly reducing power consumption.
2Productivity
If a water-cooled battery cooling system is implemented, then energy density increases and battery performance improves, but the system complexity increases
Solution Approach 1:
The patent merges the battery cooling function with the vehicle's existing HVAC refrigeration system. By integrating the battery thermal management into the refrigeration cycle, the system uses shared components (compressors, condensers, refrigerant loops) to perform both air conditioning and battery cooling functions, thereby reducing overall system complexity while maintaining water-cooled battery performance.
Solution Approach 2:
The refrigeration system is designed to serve multiple functions: it cools the battery during high-load operation and can also provide heating to the battery when needed by reversing the heat flow direction. This multi-functional approach eliminates the need for separate heating and cooling systems, simplifying the overall architecture.
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 reduces electric energy waste and significantly improves battery thermal management performance, enhancing the all-electric range by efficiently managing battery temperature without the need for an electric heater.
Implementation Method 1
a refrigerant chiller thermally connecting the first refrigeration cycle and the second refrigeration cycle
Implementation Method 2
a battery chiller thermally connecting the second refrigeration cycle and the battery cooling subsystem
Implementation Method 3
the condenser may be located on the downstream side of the battery chiller in the second refrigerant loop
Implementation Method 4
the condenser may be located on the downstream side of the battery chiller in the second refrigerant loop
Data Source
AI summary
An embodiment vehicle thermal management system includes a first refrigeration cycle including a first refrigerant loop in which a first refrigerant is circulated, a battery cooling subsystem including a battery coolant loop in which a battery-side coolant is circulated, wherein the battery coolant loop is fluidly connected to a battery, a second refrigeration cycle including a second refrigerant loop in which a second refrigerant is circulated, the second refrigeration cycle comprising a condenser thermally connected to the battery cooling subsystem, a refrigerant chiller thermally connecting the first refrigeration cycle and the second refrigeration cycle, and a battery chiller thermally connecting the second refrigeration cycle and the battery cooling subsystem, wherein the condenser is located on a downstream side of the battery chiller in the second refrigerant loop.