Battery Coolant Circuit Sharing for Low-Energy Thermal Control
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Solution Overview
Problem
Current temperature control systems for energy storage devices in vehicles are inefficient, increasing production costs, installation space, and weight, while reducing the electric vehicle's range due to the need for additional components and constant operation of the refrigerant circuit regardless of ambient temperature.
Innovation Solution
A device with a shared coolant cooler for both coolant and refrigerant circuits, allowing for variable heat transfer configurations via evaporators and condensers, enabling efficient cooling and heating by decoupling circuits based on ambient temperature, reducing the need for additional components and optimizing energy use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a coolant-refrigerant heat exchanger (chiller) is used to cool the battery at ambient temperatures above the threshold temperature, then the cooling capability is improved, but the production costs, installation space, and vehicle weight increase due to the additional air-cooled condenser
Solution Approach 1:
The patent merges the coolant circuit and refrigerant circuit by arranging the evaporator of the refrigerant circuit in thermal contact with the coolant circuit. This allows the refrigerant evaporation process to directly cool the coolant, eliminating the need for a separate chiller and reducing system weight while maintaining cooling capability at high ambient temperatures
Solution Approach 2:
The refrigerant circuit is designed to serve dual functions: it provides refrigeration for the vehicle interior and simultaneously cools the battery through the evaporator-coolant circuit thermal contact. This multi-functionality eliminates the need for separate cooling systems, reducing overall system weight and complexity
2Temperature
If the refrigerant circuit is always coupled with the coolant circuit via a chiller to enable heat dissipation independently of ambient temperatures, then the cooling capability is improved, but the energy efficiency is reduced due to constant operation of the compressor
Solution Approach 1:
The patent implements a dynamic coupling mechanism where the refrigerant circuit is thermally connected to the coolant circuit only when needed (when ambient temperature exceeds the threshold or when refrigeration is required). This dynamic configuration allows the system to switch between active cooling mode and passive operation, reducing compressor energy consumption while maintaining cooling capability when necessary
Solution Approach 2:
The system changes its operational parameters based on ambient temperature and cooling demand. The thermal coupling between refrigerant and coolant circuits is activated or deactivated according to temperature thresholds, allowing the system to optimize energy consumption by avoiding unnecessary compressor operation while maintaining adequate cooling performance
3Temperature
If an additional air-cooled condenser is arranged in the vehicle cooling module to enable cooling at high ambient temperatures, then the cooling capability is improved, but the production costs and installation space increase
Solution Approach 1:
The patent combines the refrigerant condenser with the existing vehicle cooling module infrastructure. The condenser is integrated into the available space in the cooling module, utilizing the same mounting locations and structural supports as other cooling components, thereby avoiding additional space requirements while maintaining high-temperature cooling capability
Solution Approach 2:
The refrigerant circuit components serve multiple functions: the condenser provides heat rejection for both the vehicle interior refrigeration and the battery cooling system, while the evaporator provides direct cooling to the coolant circuit. This multi-functionality reduces the need for separate dedicated cooling components, minimizing installation space requirements
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 improves energy efficiency, reduces installation space and production costs, and enhances the vehicle's range by optimizing temperature control performance across varying ambient temperatures, while maintaining effective cooling and heating capabilities.
Implementation Method 1
a refrigerant circuit (6), which can be coupled with the first coolant circuit (5) in a heat-transferring manner by means of at least one refrigerant evaporator (7)
Implementation Method 2
a coolant cooler (10) for heat transfer between the first coolant circuit (5) and an exterior environment (11) of the device (1)
Data Source
AI summary
A temperature control device of a vehicle may include an energy storage device, a first coolant circuit configured to temperature control the energy storage device, a refrigerant circuit, at least one refrigerant evaporator, a second coolant circuit, a refrigerant condenser, and a coolant cooler for transferring heat to an exterior environment. At least one section of the first coolant circuit and at least one section of the second coolant circuit may be defined by a shared circuit section. The coolant cooler may be fluidically connectable with at least one of the first coolant circuit and the second coolant circuit via the shared circuit section. The first coolant circuit may include a bypass for at least partially bypassing the coolant cooler. The first coolant circuit may include a valve device structured and arranged to distribute a first coolant flow to at least one of the shared circuit section and the bypass.