Charge Inlet Coolant Loop for Faster EV Battery Charging
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Solution Overview
Problem
Existing electric vehicle battery charging systems generate excessive heat during fast charging, limiting charging rates and increasing wait time due to reliance on radiators and fans for cooling, which also create noise and consume power.
Innovation Solution
A thermal control system that uses a fluid source at a controlled temperature to condition fluids within the charging station and vehicle, optimizing temperatures at key components to reduce heat generation and eliminate the need for active cooling systems, thereby enhancing charging efficiency and user comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If higher charging current is used to increase charging rate, then charging speed is improved, but heat generation increases limiting further rate increases
Solution Approach 1:
The system pre-cools the battery and charging components before initiating fast charging, and continuously circulates coolant through heat exchangers during charging to maintain optimal temperatures, enabling sustained high charging rates without thermal limitations
Solution Approach 2:
A coolant fluid acts as an intermediary heat transfer medium, circulating through heat exchangers connected to the battery and charging components to efficiently remove generated heat, allowing higher charging currents to be sustained without excessive temperature rise
2Temperature
If radiators and fans are used to cool the battery during charging, then temperature control is improved, but noise and power consumption increase
Solution Approach 1:
The system replaces mechanical cooling devices (fans and radiators) with a fluid-based thermal management system using heat exchangers and coolant circulation, eliminating noisy mechanical components while maintaining effective temperature control during fast charging
Solution Approach 2:
The coolant system passively removes heat through thermodynamic heat exchange processes without requiring active mechanical intervention, reducing the need for powered cooling devices and their associated noise and energy consumption
3Temperature
If radiators and fans are used for cooling during charging, then temperature control is improved, but charging time increases
Solution Approach 1:
The system pre-cools the battery and charging components before fast charging begins, and maintains continuous coolant circulation during charging, enabling the system to sustain higher charging currents for longer periods without thermal shutdowns, thereby reducing overall charging time
Solution Approach 2:
The coolant fluid serves as an efficient heat transfer intermediary, rapidly removing heat from the battery and charging components, allowing the system to maintain optimal operating temperatures and sustain high charging rates throughout the charging process, reducing total charging duration
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 improves charging speed, reduces noise, and conserves energy by managing temperature changes during battery charging, allowing for faster and more efficient charging without the need for traditional cooling mechanisms.
Implementation Method 1
a fluid source, either heated or cooled, to implement thermal control... In the case of a cooled fluid... the fluid can be used to remove heat generated during fast charging
Implementation Method 2
a charging station connector receiving the fluid at the first temperature and thermally conditioning the fluid to a second temperature; a vehicle charge inlet receiving the fluid at the second temperature and thermally conditioning the fluid to a third temperature
Data Source
AI summary
A thermal control system for use during electric battery charging includes a charging station thermally conditioning a fluid and sending the fluid to a charge inlet. The charge inlet thermally conditions the fluid and sends the fluid to one of a thermal loop or a heat exchanger. Another thermal control system includes a charging station thermally conditioning a fluid and sending the fluid to a charge inlet. The charge inlet thermally conditions the fluid and sends the fluid back to the charging station. In another thermal control system, a thermal loop supplies a fluid at a first temperature to a charge inlet. The charge inlet thermally conditions the fluid to a second temperature and returns the fluid to the thermal loop.