Dual Coolant Flow Path Air Removal for Thermal Management
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Solution Overview
Problem
Existing thermal management systems face issues with air bubbles mixing in disconnected flow paths, leading to inefficient cooling and potential overheating of components.
Innovation Solution
A thermal management system with a reserve tank and control device that executes air removal processes when the heat-exchanged device temperature is below a certain threshold, connecting flow paths to remove air bubbles and optimizing cooling operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the first flow path and second flow path are disconnected to enable independent temperature control, then temperature control flexibility is improved, but air bubbles may mix in the flow paths causing cooling inefficiency
Solution Approach 1:
The system performs air removal operations in advance when the heat-exchanged device temperature is below the first temperature threshold, before normal cooling operations begin. This preliminary action ensures that air bubbles are removed from both flow paths before they can interfere with cooling efficiency, while allowing the flow paths to be disconnected for temperature control flexibility during normal operation.
Solution Approach 2:
The control device monitors temperature as a parameter and changes the system state based on temperature thresholds. When temperature drops below the first threshold, the system switches to air removal mode by connecting flow paths and activating the pump. When temperature rises above the threshold, the system returns to normal disconnected operation, allowing temperature control flexibility while preventing air bubble accumulation.
2Reliability
If air removal process is executed continuously to prevent air bubbles, then cooling efficiency is improved, but excessive cooling and increased pump load occur
Solution Approach 1:
Instead of continuous operation, the air removal process is executed periodically based on temperature monitoring. The pump and flow path connection are activated only when the temperature drops below the first threshold, and deactivated when temperature rises above the second threshold. This periodic action maintains cooling efficiency by removing air bubbles when needed while reducing pump load and avoiding excessive cooling during normal operation.
3Productivity
If the pump is driven at high speed to remove air bubbles quickly, then air removal speed is improved, but energy consumption and pump wear increase
Solution Approach 1:
The system uses moderate pump speed rather than maximum speed for air removal. By operating the pump at a moderate speed during the periodic air removal cycles, the system achieves sufficient air bubble removal without the excessive energy consumption and wear associated with high-speed operation. The moderate speed is adequate for the relatively short duration air removal operations.
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 prevents air bubbles from mixing in flow paths, ensuring efficient cooling of components like batteries and drive devices while minimizing excessive cooling and pump load.
Implementation Method 1
The pump is configured to circulate the heat medium in each of the first flow path and the second flow path in a state where the first flow path and the second flow path are connected
Implementation Method 2
The heat-exchanged device is configured to exchange heat with the heat medium flowing through one of the first flow path and the second flow path
Implementation Method 3
The switching device is configured to switch a connection state between the first flow path and the second flow path
Data Source
AI summary
A thermal management system includes a first flow path through which a heat medium flows, a second flow path through which the heat medium flows, a reserve tank provided in the second flow path, a water pump that circulates the heat medium, and a switching device. The thermal management system executes an air removal process for the second flow path and the first flow path by connecting the second flow path and the first flow path with the switching device and driving the water pump in a case where a temperature of a heat-exchanged device is lower than a specified temperature in a state where the second flow path and the first flow path are disconnected.