Vehicle Battery Thermal System Liquid Coolant Management
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Solution Overview
Problem
Traditional battery thermal systems for vehicles rely on cabin air for cooling and warming, which results in low heat rejection, noise, vibration, limited cooling capacity, and potential blockage issues due to the use of air as a heat transfer medium.
Innovation Solution
A battery thermal system utilizing a refrigerant-to-coolant heat exchanger, a battery radiator, a valve for coolant redirection, and an electric pump to circulate liquid coolant through the battery pack, radiator, and heater, allowing for efficient cooling and heating independent of the air conditioning system and eliminating the need for cabin air intake.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If air flow from vehicle HVAC system is used to cool and warm battery pack, then system complexity is reduced, but heat transfer efficiency deteriorates due to low heat transfer coefficient of air
Solution Approach 1:
The patent transitions from using air (gas) for thermal management to using liquid coolant for cooling the battery pack. The liquid coolant system includes a coolant pump, radiator, and coolant flow paths through the battery pack, providing superior heat transfer efficiency compared to air while maintaining reasonable system complexity through integration with the vehicle's existing cooling infrastructure.
2Temperature
If battery blower motor and air rush noise are used for battery cooling, then cooling capability is provided, but interior passenger cabin noise and vibration increase
Solution Approach 1:
The patent extracts the battery cooling function from the passenger cabin air flow system. Instead of using cabin air that passes through the passenger space, the system uses a separate liquid coolant loop that circulates through the battery pack independently, eliminating noise and vibration from blower motors and air rushing through the cabin.
Solution Approach 2:
The patent replaces the pneumatic air-based cooling system with a hydraulic liquid coolant system. The liquid coolant circulates through closed-loop channels in the battery pack, providing silent and vibration-free cooling compared to air-based systems that require blower motors and create audible noise.
3Device complexity
If passenger cabin air is used for battery cooling, then existing HVAC system is utilized, but cooling capacity is limited after vehicle has been parked in sun due to high air temperatures in passenger cabin
Solution Approach 1:
The patent extracts the battery cooling function from dependence on passenger cabin air temperature. The liquid coolant system draws cooling capacity directly from the vehicle's radiator and HVAC coolant loop, bypassing the heated passenger cabin air, thereby maintaining effective cooling capacity even after the vehicle has been parked in hot sunlight.
4Ease of operation
If air inlet grille between passenger cabin and battery thermal system is used, then battery air cooling flow is enabled, but risk of accidental blockage by vehicle passengers increases
Solution Approach 1:
The patent replaces the air-based cooling system requiring physical inlet grilles with a liquid coolant system that uses sealed fluid pathways. The coolant circulates through closed-loop channels within the battery pack, eliminating the need for external air inlet grilles and thereby removing the risk of blockage by passengers or debris, ensuring reliable cooling flow.
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 provides enhanced heat transfer, reduces noise and vibration, ensures continuous battery cooling and heating capabilities, and avoids cabin air intake issues, allowing for flexible component placement and improved passenger space utilization.
Implementation Method 1
a refrigerant-to-coolant heat exchanger that selectively receives refrigerant from the vehicle air conditioning system
Implementation Method 2
a battery radiator located adjacent to a cooling fan
Implementation Method 3
a battery radiator located adjacent to a cooling fan
Implementation Method 4
a cooling fan located adjacent to the battery radiator and configured to draw air through the battery radiator
Implementation Method 5
an electric pump for pumping the liquid coolant through the battery pack, the valve, the refrigerant-to-coolant heat exchanger and the battery radiator
Implementation Method 6
a battery coolant heater
Data Source
AI summary
A battery thermal system for use in a vehicle having a power plant, an air conditioning system and a battery pack, and a method of operation, is disclosed. The battery thermal system may include a refrigerant-to-coolant heat exchanger that selectively receives a refrigerant from the vehicle air conditioning system; a battery radiator located adjacent to a cooling fan; a valve that receives a liquid coolant from the battery pack and selectively redirects the liquid coolant to the refrigerant-to-coolant heat exchanger and the battery radiator; and an electric pump for pumping the liquid coolant through the battery pack, the valve, the refrigerant-to-coolant heat exchanger and the battery radiator. The battery thermal system may also include a battery coolant heater for selectively heating the coolant that flows into the battery pack.