Brake Resistor Battery Preheating in EV Thermal Management

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Solution Overview

Problem

Electric vehicles generate significant waste heat, which can negatively affect battery performance and lifespan, and fuel cell operation, leading to reduced thermal efficiency and increased power consumption, thus impacting vehicle range and lifespan.

Innovation Solution

A thermal management system that includes an electric power source loop thermally coupled to a common radiator, a brake resistor loop, and an alternate cooling system, where the system dynamically switches between modes to optimize heat dissipation and pre-heating of batteries based on ambient temperature, using the brake resistor to pre-heat batteries when necessary.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If waste heat from battery and fuel cell is captured and routed to radiator for removal, then thermal management is achieved, but thermal efficiency is reduced and power consumption increases

Engineering Contradiction:

Improvewaste heat removalVSAvoidthermal efficiency

Core Design Contradiction:

TemperatureVSLoss of energy

Solution Approach 1:

The patent converts the harmful waste heat into a beneficial resource by using it to pre-heat batteries in cold conditions and to supplement heating demands, thereby improving overall thermal efficiency while still achieving waste heat removal when necessary

Inventive Principle:

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

Solution Approach 2:

The thermal management system is designed to perform multiple functions: waste heat removal via radiator, waste heat recovery for battery pre-heating, and waste heat utilization for cabin heating, allowing the same heat source to serve different purposes based on system needs

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If waste heat is used to pre-heat batteries in low ambient temperature, then battery performance is improved, but additional power consumption occurs

Engineering Contradiction:

Improvebattery performanceVSAvoidpower consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The system converts waste heat from the fuel cell and battery into a useful heating resource for battery pre-heating, eliminating the need for additional power consumption while improving battery performance in cold conditions

Inventive Principle:

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

Solution Approach 2:

The thermal management system uses the vehicle's own waste heat to service the heating needs of the battery, creating a self-sufficient thermal management approach that does not require external power input

Inventive Principle:

Principle #25Self-service

3Duration of action of stationary object

If thermal management system manages heat dissipation effectively, then battery lifespan is extended, but system complexity increases

Engineering Contradiction:

Improvebattery lifespanVSAvoidsystem complexity

Core Design Contradiction:

Duration of action of stationary objectVSDevice complexity

Solution Approach 1:

The thermal management system uses a unified multi-functional architecture that handles waste heat removal, battery pre-heating, and cabin heating through integrated control, reducing overall system complexity compared to separate dedicated systems for each function

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent merges the waste heat removal path and waste heat recovery path into a single integrated thermal management system, combining multiple functions into one coordinated system that manages all thermal aspects efficiently

Inventive Principle:

Principle #5Merging (Combining)

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 approach enhances thermal efficiency, reduces power consumption, extends battery life, and increases vehicle range by effectively managing heat generation and dissipation, particularly in low ambient temperatures.

Implementation Method 1

When an ambient temperature is less than a first threshold, the brake resistor is configured to pre-heat at least one of the one or more battery packs

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

waste heat from the fuel cell stack and/or battery is captured by a coolant

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

routed to a radiator, thereby removing the waste heat from the system by releasing it to the ambient environment

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 4

releasing it to the ambient environment

Methodology Applied

Scientific EffectThermal radiation: Thermal Radiation

Data Source

PatentUS11772450B2Thermal management systems and methods with heating component

Publication Date: 2023.10.03 HYROAD NETWORKS LLC

AI summary

A vehicle has a thermal management system that comprises an electric power source loop comprising at least one battery. The thermal management system further comprises a heating component thermally coupled to the electric power source loop. When an ambient temperature is less than a first threshold, the heating component pre-heats the at least one battery. In exemplary embodiments, the heating component includes at least one brake resistor that is coupled to the electric power source loop.