Dual Loop Thermal Management for Electric Vehicle Battery Cooling
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Solution Overview
Problem
Traditional thermal management systems for motor vehicles, designed for internal combustion engines, are inefficient in vehicles with reduced or eliminated ICE use, such as battery electric vehicles, as they generate less thermal energy and require more complex and costly systems to manage thermal energy effectively.
Innovation Solution
A dual thermal fluid loop system with a coolant loop for battery cooling and a refrigerant loop for passenger compartment cooling, controlled by a controller to optimize energy transfer and reduce hardware complexity and cost, using a compressor and condenser with adjustable power and airflow settings to manage thermal energy efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional thermal management systems designed for internal combustion engines are applied to battery electric vehicles, then thermal energy can be managed, but system complexity and hardware cost increase significantly due to reduced thermal energy availability
Solution Approach 1:
The patent combines the battery cooling function and passenger compartment cooling function into a single integrated thermal management system. The refrigerant loop serves dual purposes: cooling the battery through the chiller and cooling the passenger compartment through the evaporator, eliminating the need for separate cooling circuits and reducing overall system complexity
Solution Approach 2:
The chiller component performs multiple functions within the system. It acts as a heat exchanger that transfers thermal energy from the battery cooling loop to the refrigerant loop, enabling the refrigerant system to serve both battery thermal management and cabin cooling functions, thereby reducing hardware requirements
2Reliability
If traditional thermal management systems are used in battery electric vehicles, then thermal control is achieved, but hardware cost increases due to additional components needed for low thermal energy environments
Solution Approach 1:
The system merges battery cooling and cabin cooling into one integrated refrigerant loop, reducing the total number of components required. This consolidation lowers hardware costs while maintaining effective thermal control for both battery and passenger compartment
Solution Approach 2:
The refrigerant loop is designed to perform multiple functions: cooling the battery via the chiller, cooling the passenger compartment via the evaporator, and dissipating heat to the environment via the condenser. This multi-functionality reduces the need for separate dedicated systems, thereby reducing overall hardware cost
3Temperature
If the compressor operates at high power settings for battery cooling, then effective cooling is achieved, but energy consumption increases
Solution Approach 1:
The controller dynamically adjusts the compressor power setting based on real-time thermal conditions. When battery cooling is required, the compressor operates at higher power settings; when cabin cooling is sufficient or battery temperature is acceptable, the compressor reduces power consumption, optimizing energy usage while maintaining effective cooling when needed
Solution Approach 2:
The system incorporates temperature sensors that continuously monitor battery and cabin temperatures, providing feedback to the controller. The controller uses this feedback to adjust compressor power settings appropriately, ensuring effective cooling only when and where needed, thereby reducing unnecessary energy consumption
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 reduces complexity, cost, and mass, while improving thermal energy management, enhancing reliability and safety, and reducing range anxiety by efficiently collecting, storing, and distributing thermal energy in vehicles with reduced ICE usage.
Implementation Method 1
a chiller such that the first thermal fluid loop is configured to selectively transfer thermal energy among the vehicle battery and the chiller
Implementation Method 2
the condenser is configured to transfer thermal energy from the second thermal fluid loop to ambient air
Data Source
AI summary
A vehicle includes a thermal energy management system with first and second thermal fluid loops. The first thermal fluid loop includes a coolant pump configured to circulate a coolant through a vehicle battery and a chiller. The second thermal fluid loop is configured to circulate a refrigerant through the chiller, a compressor, and at least one condenser. The controller is configured to control the thermal energy management system according to a passenger compartment cooling mode and a battery cooling mode. In the passenger compartment cooling mode the compressor is operated at a first power setting. In the battery cooling mode the compressor is operated at a second power setting and the chiller is controlled to transfer thermal energy from the first thermal fluid loop to the second fluid thermal loop. The second power setting is less than the first power setting.