Actively Cooled Totes with Central Heat Reject for EV Range
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Solution Overview
Problem
Current cold chain transport systems, relying on compressor-based refrigeration, require constant operation, penetrate vehicle warranties, separate temperature zones, and significantly degrade electric vehicle range, while passive cooling methods are costly and environmentally damaging.
Innovation Solution
Implementing actively cooled totes with a central heat reject subsystem and on-demand thermal management using thermoelectric units, integrated with automated controls and monitoring, allowing for efficient temperature control without external penetration and minimizing power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If compressor-based refrigeration systems are used to maintain temperature in vehicles, then temperature control is achieved, but power consumption increases significantly degrading electric vehicle range
Solution Approach 1:
The system divides the cooling function into multiple independent thermoelectric modules distributed throughout the cargo space, each capable of localized cooling. This replaces the single high-power compressor system with multiple low-power modular units, reducing overall power consumption while maintaining temperature control.
Solution Approach 2:
The patent replaces the mechanical compressor-based refrigeration system with solid-state thermoelectric cooling modules. This substitution eliminates the need for moving parts, refrigerant circulation, and high-power compression, thereby significantly reducing power consumption and extending electric vehicle range.
2Power
If compressor-based refrigeration systems are installed in vehicles, then cooling capability is provided, but vehicle warranty is voided due to external penetration requirements
Solution Approach 1:
The cooling system is segmented into multiple small modular units that can be installed within the existing cargo space without requiring penetration of the vehicle body. Each module is self-contained and can be mounted on shelves or walls, preserving the vehicle's structural integrity and warranty.
Solution Approach 2:
The thermoelectric cooling modules are designed to nest within the existing vehicle structure, integrating with cargo shelves and walls without external modifications. This nested integration allows the cooling system to be installed internally without penetrating the vehicle's exterior or voiding warranties.
3Adaptability or versatility
If tri-temperature trucks with multiple zones are used, then diverse temperature requirements are met, but device complexity increases due to dividers and multiple systems
Solution Approach 1:
The system uses multiple independent thermoelectric modules that can be individually controlled to create different temperature zones. Each module operates independently, allowing flexible configuration of temperature zones without requiring physical dividers or complex integrated systems.
Solution Approach 2:
The temperature zones are dynamically configurable through independent control of each thermoelectric module. Users can adjust temperature settings and zone configurations programmatically, replacing static physical dividers with flexible electronic control, thereby reducing structural complexity while maintaining versatility.
4Temperature
If compressor-based refrigeration is used, then cooling is provided, but environmental harm increases due to refrigerant use and energy consumption
Solution Approach 1:
The patent replaces compressor-based refrigeration that uses harmful refrigerants with solid-state thermoelectric cooling modules. This substitution eliminates refrigerant leakage risks and reduces energy consumption, thereby minimizing environmental harm while maintaining the cooling function.
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 efficient, on-demand cooling of specific areas within vehicles, extending electric vehicle range, reducing energy costs, and minimizing environmental impact by using sustainable refrigerants and eliminating the need for bulk compressor systems.
Implementation Method 1
an active cooler including: an enclosed chamber; and a thermoelectric unit positioned inside the enclosed chamber and operable to cool the enclosed chamber
Implementation Method 2
a heat exchanger positioned outside the enclosed chamber and in thermal communication with the thermoelectric unit and operable to transfer heat from the thermoelectric unit to the ambient environment
Data Source
AI summary
Systems and methods for thermal management are provided. In some embodiments, a vehicle for transporting one or more actively cooled totes, the vehicle includes: a central heat reject subsystem operable to reject heat from the one or more actively cooled totes; and an attachment mechanism for moving heat from the one or more actively cooled totes to the central heat reject subsystem.