Conductive Heat Paint Warming for EV Coolant and Oil Loops
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Solution Overview
Problem
Vehicle powertrain systems, particularly electrified powertrains, experience significant efficiency degradation at sub-zero temperatures due to challenges in thermal management and battery operation, necessitating improved methods for rapid warming.
Innovation Solution
A thermal system utilizing electrically conductive heat paint coatings on interior surfaces of powertrain components that come into contact with thermal fluids, which are electrically heated to rapidly warm the components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional thermal management systems are used in electrified powertrains, then the system structure is simple, but the warming speed at sub-zero temperatures is insufficient and battery efficiency degrades significantly
Solution Approach 1:
The patent combines the thermal management function with the existing coolant circulation system by integrating electrically conductive heat paint coatings on coolant channels and battery components. This merging approach enables the coolant system to serve dual purposes: traditional cooling and rapid heating through resistive heating of the heat paint coating, thereby improving warming speed without adding separate heating system complexity
Solution Approach 2:
The patent replaces mechanical heating devices (such as traditional heating elements or heat pumps) with an electrical field-based solution using electrically conductive heat paint coating. When electric current is applied to the heat paint coating on coolant channels and battery components, it generates heat directly through resistive heating, eliminating the need for complex mechanical heating mechanisms while achieving rapid warming
2Temperature
If traditional heating methods are added to warm powertrain components, then the warming effectiveness improves, but the mass, cost, and complexity increase significantly
Solution Approach 1:
The patent uses thin-film electrically conductive heat paint coatings applied directly to the surfaces of coolant channels and battery components. These thin film coatings have negligible mass compared to traditional bulk heating elements, yet they effectively transfer heat to the coolant and battery components when electric current is applied, thereby increasing component temperature without significant mass penalty
Solution Approach 2:
The patent changes the electrical parameter (electrical conductivity) of the surface materials by applying conductive heat paint coatings. This allows the surfaces to directly respond to electrical input and generate heat through resistive heating, providing a lightweight alternative to mechanical heating systems while achieving the desired temperature increase
3Use of energy by moving object
If electrically conductive heat paint coatings are applied to coolant channels, then the heating efficiency improves, but the manufacturing complexity increases
Solution Approach 1:
The patent employs heat paint coatings that can be applied as disposable or easily replaceable surface treatments on coolant channels and battery components. This approach allows for simple application processes (spraying, brushing, or dipping) without requiring complex integrated manufacturing steps, thereby maintaining manufacturing ease while achieving high heating efficiency through the conductive coating
4Measurement precision
If the heat paint coating is applied to interior surfaces of powertrain components, then the thermal management precision improves, but the manufacturing precision requirements increase
Solution Approach 1:
The patent changes the surface property (electrical conductivity) of powertrain components by applying heat paint coatings, enabling precise thermal management through controlled electrical current application. The coating's uniform electrical properties allow for predictable and precise heat generation when voltage is applied, improving thermal management precision even if the coating application itself has moderate manufacturing tolerances
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 effectively and efficiently warms electrified powertrain components without adding significant mass, cost, or complexity, providing precise thermal management and improved efficiency and sustainability.
Implementation Method 1
The heat paint coating is connected to a power source and configured to selectively receive an electric current to heat the heat paint coating and thereby heat the oil thermal fluid to rapidly warm the electric traction motor during low temperature conditions
Data Source
AI summary
A vehicle thermal system includes a coolant loop configured to circulate a coolant for heating/cooling of the electrified powertrain, an oil loop configured to circulate an oil thermal fluid for heating/cooling of the electrified powertrain, and a heat exchanger fluidly coupled to the coolant loop and the oil loop. An electric traction motor is fluidly coupled to the coolant loop and the oil loop, and an interior surface of the electric traction motor includes an electrically conductive heat paint coating configured to come into contact with at least one of the coolant and the oil thermal fluid for heating/cooling of the electric traction motor. A power source is electrically coupled to the heat paint coating and configured to selectively supply an electric current to heat the heat paint coating and thereby heat the coolant and/or oil thermal fluid to rapidly warm the electric traction motor during low temperature conditions.