Charging energy recapture assembly and method
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Solution Overview
Problem
Existing electrified vehicle charging systems do not effectively utilize the thermal energy generated during direct current charging, which is often wasted and could be harnessed for other purposes.
Innovation Solution
A charging energy recapture assembly and method that utilizes a fluid loop system to transfer thermal energy from the traction battery to a charger fluid, which is then circulated back to the charging station, allowing the thermal energy to be used for heating water, buildings, or generating electricity through a thermoelectric module, without mixing with the vehicle's fluid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If thermal energy from charging is not utilized, then the system is simple, but energy is wasted
Solution Approach 1:
The patent introduces a charger fluid as an intermediary substance that carries thermal energy from the charger to various uses. The charger fluid circulates through a fluid loop system, absorbing thermal energy during DC charging and transporting it to thermal exchange devices or storage tanks, thereby enabling energy recovery without directly involving the vehicle's internal fluid systems
Solution Approach 2:
The patent divides the thermal energy recovery system into separate functional components: a charger fluid loop for thermal transport, a thermal exchange device for heat transfer, and optional storage or utilization systems. This segmentation allows the thermal management system to operate independently from the vehicle's primary cooling system, reducing overall system complexity while enabling energy recovery
2Loss of energy
If charger fluid is mixed with vehicle fluid, then thermal transfer is efficient, but fluid contamination occurs
Solution Approach 1:
The charger fluid acts as an intermediary medium that transfers thermal energy without mixing with the vehicle's internal fluids. The fluid loop system is designed with separate circulation paths, using heat exchangers or thermal exchange devices to transfer heat between the charger fluid and vehicle components, thereby preventing contamination while maintaining effective thermal transfer
Solution Approach 2:
The patent extracts the thermal energy transfer function from the vehicle's internal fluid system by introducing a separate charger fluid loop. This extraction allows thermal energy to be recovered and utilized independently, preventing the charger fluid from contaminating the vehicle's battery cooling fluid or other internal fluids while still achieving efficient heat transfer
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 enables the efficient utilization of thermal energy generated during charging, reducing energy waste and providing additional benefits such as pre-heating water or buildings, and generating electrical energy for external loads.
Implementation Method 1
transferred thermal energy from the vehicle fluid to the charger fluid
Implementation Method 2
transferred thermal energy from the vehicle fluid to the charger fluid at a position outside of the traction battery
Implementation Method 3
The thermoelectric module generates electrical energy in response to the temperature difference that is used to power a load external to the electrified vehicle
Data Source
AI summary
An exemplary charging energy recapture assembly includes a fluid loop outside a traction battery of an electrified vehicle. The fluid loop communicates a charger fluid through a charger to the electrified vehicle and returns the charger fluid to a charging station without combining the charger fluid with a vehicle fluid. An exemplary charging energy recapture method includes circulating a charger fluid through a charger between a charging station and an electrified vehicle without the charger fluid commingling with a vehicle fluid or communicating through a traction battery of the electrified vehicle.