EV Charging Module Bypass Cooling to Reduce Thermal Stress
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Solution Overview
Problem
Conventional charging devices in electric vehicles have a shorter service life due to thermal stress from coolant flow during driving operations, which is not necessary when the vehicle is not charging.
Innovation Solution
A charging device module with an internal cooling circuit connected to a vehicle's superordinate cooling circuit, featuring a bypass line and an actuable valve that controls coolant flow only during charging operations, minimizing heat transfer and thermal loads on the charging device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the charging device is connected to the superordinate cooling circuit during driving operation, then the cooling circuit can cool the charging device, but the charging device is exposed to unnecessary thermal loads and heat transfer that reduce its service life
Solution Approach 1:
The patent applies a dynamically controllable valve (electromagnetic or electronically controlled) that adjusts the coolant flow path based on operational conditions. During charging operation, the valve directs coolant through the charging device for cooling. During driving operation, the valve redirects coolant through a bypass line, preventing unnecessary thermal exposure. This dynamic switching mechanism resolves the contradiction by making the cooling system adaptive to actual thermal needs.
Solution Approach 2:
The cooling circuit is segmented into two distinct paths: one leading through the charging device and another through a bypass line. The valve controls which path the coolant takes, allowing independent management of cooling needs. This segmentation enables the system to provide cooling when needed while avoiding unnecessary thermal exposure, thereby extending service life.
2Duration of action of stationary object
If coolant flows continuously through the charging device, then the charging device is always cooled, but thermal stress during non-charging operations reduces the charging device's service life
Solution Approach 1:
The cooling flow is made periodic rather than continuous. The valve switches between charging operation mode (coolant flows through charging device) and driving operation mode (coolant bypasses charging device). This periodic activation of cooling only when necessary (during charging) eliminates continuous thermal stress while maintaining cooling availability when required.
Solution Approach 2:
The control system uses information about the vehicle's operational state (charging vs. driving) to automatically control the valve position. The system self-regulates the cooling flow based on actual thermal needs, activating cooling during charging operation and deactivating it during driving operation, thereby preventing unnecessary thermal exposure.
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 solution extends the service life of the charging device by preventing unnecessary heat exposure during driving operations and allowing efficient cooling only when needed, reducing thermal stress and potential overheating.
Implementation Method 1
an internal cooling circuit for cooling the charging device
Implementation Method 2
coolant from the superordinate cooling circuit of the vehicle flows through the charging device
Implementation Method 3
the superordinate cooling circuit has a heat exchanger for giving off heat to the area surrounding the vehicle
Implementation Method 4
a heat exchanger for giving off heat to the area surrounding the vehicle
Data Source
AI summary
A charging device module for installation in an electrically driveable vehicle, including a charging device and an internal cooling circuit for cooling the charging device, wherein the internal cooling circuit has connections for connection to a superordinate cooling circuit of the vehicle, wherein the connections comprise at least one inlet and at least one outlet, and a bypass line connects the at least one inlet to the at least one outlet while bypassing the internal cooling circuit, wherein an actuable valve is associated with the at least one inlet, by which valve the flow of coolant through the internal cooling circuit and the bypass line can be controlled.