EV Battery Direct Cooling With Waste Heat Recovery Layout
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Solution Overview
Problem
Existing thermal management systems for electric vehicles are complex, costly, and inefficient due to the need for additional heat exchangers and pipelines to manage battery pack temperature, which affects the battery's performance and longevity.
Innovation Solution
A vehicle thermal management system that integrates a direct-cooling device with the battery pack and a waste heat utilization branch, eliminating the need for additional heat exchangers and pipelines by using refrigerant for direct heat exchange with the battery pack, and incorporating a heat sink for external heat exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an additional battery heat exchange circuit with separate heat exchanger and pipelines is provided, then the battery pack can be heated and cooled, but the pipeline arrangement becomes complex and costs increase
Solution Approach 1:
The patent merges the battery thermal management function with the existing air conditioning refrigerant circulation system. The refrigerant circulation system is configured to directly cool the battery pack by making the refrigerant flow through channels formed by the battery housing and battery modules, eliminating the need for separate battery heat exchange circuits, dedicated heat exchangers, and additional pipelines. This integration simplifies the overall system structure while maintaining effective temperature control for the battery.
2Reliability
If an additional battery heat exchange circuit with separate heat exchanger and pipelines is provided, then the battery pack can be heated and cooled, but costs increase
Solution Approach 1:
The refrigerant circulation system is designed to serve multiple functions: it cools the battery pack during charging and discharging operations, and it also provides air conditioning for the passenger compartment. The same compressor, condenser, expansion valve, and refrigerant lines are used for both battery thermal management and cabin cooling, eliminating the need for dedicated components and reducing overall system cost.
3Reliability
If a separate battery heat exchange circuit is provided, then heating and cooling functions are achieved, but heat exchange efficiency is reduced due to external environment interference
Solution Approach 1:
The refrigerant acts as an intermediary heat transfer medium that directly contacts the battery components through specially designed flow channels. The refrigerant absorbs heat from the battery modules during high-temperature operations and releases heat during low-temperature operations, providing efficient thermal management that is not affected by external environmental conditions. This direct heat exchange through the refrigerant intermediary ensures stable temperature control.
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 system simplifies pipeline arrangements, reduces costs, and enhances heat exchange efficiency, ensuring the battery operates within a suitable temperature range, improving efficiency, endurance, and safety while effectively utilizing waste heat.
Implementation Method 1
The refrigerant is directly used to exchange heat for the battery pack
Implementation Method 2
a heat exchanger provided at the battery pack for heat exchange with the battery pack
Implementation Method 3
The second thermal management system includes a heat sink
Data Source
AI summary
A system for thermal management, includes a first thermal management system including a compressor and a battery pack, and a second thermal management system including a heat sink, a heat exchanger, and a waste heat utilization branch for a high-voltage system. A water pump and a high-voltage system cooling branch passing through the high-voltage system are disposed on the waste heat utilization branch. A cooling liquid outlet of the heat exchanger communicates with an inlet of the waste heat utilization branch. An outlet of the waste heat utilization branch communicates with a cooling liquid inlet of the heat exchanger. A direct-cooling device is disposed on the battery pack. An outlet of the compressor communicates with a first port of the direct-cooling device. A second port of the direct-cooling device communicates with a refrigerant inlet of the heat exchanger. A refrigerant outlet of the heat exchanger communicates with an inlet of the compressor.