Electric Drivetrain Cooling With Condensation Return Flow
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Solution Overview
Problem
Existing cooling devices for electric drive train components are not efficient in controlling temperature and ensuring a reliable coolant supply, leading to suboptimal performance and lifespan of these components.
Innovation Solution
A cooling device with a heat exchanger that transforms gaseous coolant into liquid coolant, using a coolant collection channel oriented below the heat exchanger to create a suction effect, ensuring continuous coolant flow and efficient heat extraction, and optionally integrating with the electric machine or transmission for enhanced compactness and cooling performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional cooling device uses liquid coolant circulation, then the cooling device can remove heat from the electric drive train component, but the cooling efficiency is limited and a large amount of coolant is required to achieve sufficient cooling
Solution Approach 1:
The patent utilizes phase transition of coolant from liquid to gas state during evaporation to absorb large amounts of heat from the electric drive train component, and then condenses the gas back to liquid in the heat exchanger. This phase change mechanism enables high cooling efficiency with a smaller quantity of coolant compared to conventional liquid-only cooling systems.
2Volume of moving object
If the cooling device uses a compact design, then the device size is reduced, but the heat exchanger may not effectively condense the gaseous coolant into liquid coolant
Solution Approach 1:
The patent positions the end of the coolant collection channel at a lower vertical level than the heat exchanger, utilizing gravitational force in the vertical dimension to create a suction effect. This dimensional arrangement ensures reliable coolant condensation and continuous circulation while maintaining a compact overall device structure.
3Device complexity
If the coolant collection channel is arranged horizontally, then the device structure is simplified, but the condensed coolant cannot be effectively collected and returned to the heat exchanger
Solution Approach 1:
The patent transitions from a horizontal to a vertical arrangement of the coolant collection channel, utilizing the vertical dimension and gravitational force to create a suction effect that draws condensed coolant back to the heat exchanger. This vertical configuration enhances coolant circulation efficiency while maintaining structural simplicity.
4Device complexity
If the cooling device operates without a suction effect, then the system is simpler, but the continuous supply of liquid coolant to the electric drive train component cannot be ensured
Solution Approach 1:
The patent employs a self-service mechanism where the phase change of coolant from gas to liquid in the heat exchanger naturally creates a suction effect due to density difference and gravitational force. This self-generated suction ensures continuous circulation and supply of liquid coolant without requiring additional active pumping components.
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 effectively controls the temperature of electric drive train components by efficiently extracting heat and providing a consistent supply of liquid coolant, enhancing performance and lifespan while maintaining a compact design.
Implementation Method 1
a heat exchanger (26) being configured to extract heat from the gaseous coolant such that the gaseous coolant is at least partially transformed into liquid coolant
Implementation Method 2
at least a portion of the coolant is gasified or vaporized when being in contact with hot or warm parts of the electric drivetrain component
Implementation Method 3
Since the condensed coolant is driven at least partially along the vertical direction by gravity, it creates a suction effect moving additional gaseous coolant into the heat exchanger
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The disclosure relates to a cooling device (24) for an electric drive train component (21). The cooling device (24) comprises a coolant inlet port (32) being configured to receive gaseous coolant (G) from the electric drive train component (21) and a coolant outlet port (34) being configured to deliver liquid coolant (L) to the electric drive train component (21). Moreover, the cooling device (24) comprises a heat exchanger (26) being configured to extract heat from the gaseous coolant (G) such that the gaseous coolant (G) is at least partially transformed into liquid coolant (L). The cooling device (24) also comprises a coolant collection channel (40). An end of the coolant collection channel (40) being arranged adjacent to the coolant outlet port (34) is located on a lower vertical level than the heat exchanger (26). Furthermore, an electric drive train assembly (12) comprising an electric machine (18) and such a cooling device (24) is explained. Also, a method for operating a cooling device (24) for an electric drive train component (21) and a method for cooling an electric drive train component (21) are presented. Moreover, a vehicle (10) comprising an electric drive train assembly (12) is shown.