Integrated Coolant Polishing Filter for Low-Conductivity EV Cooling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cooling systems for electrical components in electrified systems, such as electric vehicles, face challenges with maintenance intervals for polisher assemblies and filters, leading to increased costs and the risk of coolant spills during maintenance, as well as inefficiencies in removing ions from low-conductivity coolant that can increase conductivity over time.
Innovation Solution
A continuous cooling loop system without bypass valves or plumbing, where an ionically active polymer is integrated within a filter bed to continuously polish low-conductivity coolant as it flows through electrical components, aligning the service life of the filter and polisher material to reduce maintenance burdens.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a polisher assembly is used to remove conductive ions from low-conductivity coolant, then the conductivity of the coolant is reduced, but the polisher assembly requires separate maintenance and may cause coolant spills
Solution Approach 1:
The patent combines the polisher assembly with the filter housing into a single integrated unit. The polisher media is contained within the filter housing, allowing both filtration and ion removal functions to be performed by one component that is replaced as a single unit, eliminating separate maintenance of polisher assemblies and reducing coolant spill risk.
Solution Approach 2:
The filter housing serves multiple functions: it acts as both a filter element and a polisher assembly housing. This multi-functional design consolidates what would traditionally be separate components into one universal unit that handles both particulate filtration and conductive ion removal simultaneously.
2Reliability
If separate polisher assemblies and filters are used, then ion removal and filtration are performed, but the number of maintenance intervals increases
Solution Approach 1:
The patent merges the filter element and polisher assembly into a single replaceable unit housed within the filter housing. This integration means that one maintenance action replaces both the filter and polisher media simultaneously, reducing the number of separate maintenance intervals and simplifying service procedures.
3Reliability
If low-conductivity coolant is used in electrical systems, then the risk of short-circuit is reduced, but conductive ions accumulate over time increasing conductivity
Solution Approach 1:
The patent implements continuous ion removal by integrating the polisher media into the coolant circulation path. As coolant flows through the filter housing during normal operation, conductive ions are continuously removed from the coolant, maintaining low conductivity over extended periods and prolonging the effective service life of the coolant.
Solution Approach 2:
The polisher media within the filter housing automatically removes conductive ions from the coolant as it passes through during normal system operation. The system performs self-maintenance of coolant quality without requiring external intervention, continuously restoring low conductivity conditions.
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 reduces the number of maintenance intervals, minimizes the risk of coolant spills, and ensures continuous ion removal from low-conductivity coolant, thereby prolonging its effectiveness and reducing the burden on end users.
Implementation Method 1
an ionically active polymer is integrated within a filter bed to continuously polish low-conductivity coolant
Implementation Method 2
Coolants are commonly used to transfer the heat away from the electrical components and into a coolant
Data Source
AI summary
The present disclosure provides an electrical system for an electrical vehicle, comprising: at least one electrical component; a cooling loop including a low-conductivity coolant coupled to each of the at least one electrical component; and at least one filter in the cooling loop. The cooling loop is configured to flow or circulate the low-conductivity coolant through each of the at least one battery and/or electrical component and the at least one filter includes a polisher material.