EV Battery Thermal Loop Using Motor Waste Heat and Fire Suppression

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Solution Overview

Problem

Traditional electric vehicle thermal management systems face challenges in effectively controlling battery temperature, leading to potential fires and reduced performance, especially during thermal runaway, and are inefficient in cold conditions, while additional fire extinguishing systems occupy space and increase energy consumption.

Innovation Solution

A dual-loop thermal management system using first and second heat conducting agents, connected to the battery and driving motor respectively, with a conveying mechanism to redirect heat agents during thermal runaway and a release mechanism to prevent fires, without the need for an additional fire extinguishing system, allowing for efficient heating and cooling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an additional fire extinguishing system is added to the battery liquid cooling system, then the fire extinguishing capability is improved, but the vehicle space is occupied and energy consumption increases

Engineering Contradiction:

Improvefire extinguishing capabilityVSAvoidvehicle space

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The battery liquid cooling system is designed to perform multiple functions: normal thermal management during operation and fire extinguishing during thermal runaway. The coolingant circulation system serves both cooling purposes and fire suppression purposes, eliminating the need for a separate fire extinguishing system and thereby saving vehicle space while maintaining fire safety capability

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The invention merges the fire extinguishing function with the existing battery liquid cooling system. The coolingant delivery mechanism and circulation system are combined to serve both normal cooling operations and emergency fire suppression, integrating two previously separate functions into a single unified system that reduces overall system complexity and space requirements

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If an additional fire extinguishing system is added to the battery liquid cooling system, then the fire extinguishing capability is improved, but the energy consumption increases

Engineering Contradiction:

Improvefire extinguishing capabilityVSAvoidvehicle energy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The battery liquid cooling system is designed to perform multiple functions: normal thermal management during operation and fire extinguishing during thermal runaway. The coolingant circulation system serves both cooling purposes and fire suppression purposes, eliminating the need for a separate fire extinguishing system and thereby reducing overall energy consumption while maintaining fire safety capability

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

Inventive Principle:

Principle #5Merging (Combining)

3Temperature

If traditional PTC heating solution is used for battery heating in cold conditions, then the heating function is provided, but the heating efficiency is low and energy consumption is high

Engineering Contradiction:

Improvebattery temperatureVSAvoidheating energy consumption

Core Design Contradiction:

TemperatureVSUse of energy by moving object

Solution Approach 1:

The invention converts the waste heat generated by the motor during operation into a useful resource for battery heating. The motor cooling system, which normally dissipates heat to the environment, is instead used to transfer heat to the battery when heating is needed, turning what would be wasted energy into a beneficial heating source and significantly reducing the energy consumption required for battery thermal management in cold conditions

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The invention introduces a heat exchange mechanism as an intermediary between the motor cooling system and the battery thermal management system. This heat exchanger enables efficient thermal energy transfer from the motor to the battery, facilitating effective heating of the battery using motor waste heat while maintaining optimal operating temperatures for both components

Inventive Principle:

Principle #24Intermediary (Mediator)

4Quantity of substance

If coolant capacity in the battery liquid cooling system is limited, then the system remains compact, but the fire extinguishing capability is insufficient when coolant is exhausted

Engineering Contradiction:

Improvecoolant capacityVSAvoidfire extinguishing capability

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The system includes a coolingant storage tank that pre-stores additional coolingant ready for emergency use. When thermal runaway occurs and the circulation system's coolant is depleted, the stored coolingant is automatically delivered to the battery through the coolingant delivery mechanism, ensuring continuous fire suppression capability without requiring a large-volume coolant system during normal operation

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The coolingant delivery mechanism is designed to dynamically respond to thermal runaway conditions by activating the storage tank discharge and directing stored coolingant to the battery. This dynamic activation allows the system to transition from a compact low-volume state during normal operation to a high-capacity fire suppression state when needed, optimizing both space efficiency and fire safety

Inventive Principle:

Principle #15Dynamics

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 manages battery and motor temperatures, preventing fires and improving safety by utilizing existing heat sources for efficient heating, thus saving space and energy.

Implementation Method 1

the first heat conducting agent and the second heat conducting agent are released to the battery to cool or extinguish the battery system

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Implementation Method 2

The first loop transmits the first heat conducting agent to the first temperature control mechanism for cooling or heating, and then transmits it to the battery for heat exchange with the battery

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentEP4070987B1Electric vehicle thermal management system, battery thermal management method and electric vehicle

Publication Date: 2024.08.07 MICROVAST POWER SYST CO LTD

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AI summary

Disclosed are an electric vehicle thermal management system, a battery thermal management method and an electric vehicle. The electric vehicle thermal management system comprises a first loop (100), a second loop (200), a first temperature control mechanism (300), a second temperature control mechanism (400), a conveying mechanism (500) and a release mechanism (600), wherein the first loop (100) transfers a first thermal conduction agent; a battery (700) and the first temperature control mechanism (300) are respectively connected to the first loop (100); the second loop (200) transfers a second thermal conduction agent; the second temperature control mechanism (400) and a driving electric motor (800) are respectively connected to the second loop (200); the conveying mechanism (500) is respectively in communication with the first loop (100) and the second loop (200); and the release mechanism (600) is in communication with the first loop (100), such that a battery fire disaster is effectively prevented from occurring, and the safety of the vehicle is improved.