Dual-Mode Coolant Loops for EV Battery and Drive Train Cooling
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Solution Overview
Problem
Current thermal management systems in electric vehicles are inefficient and overly complex due to the use of multiple independent subsystems, which complicates the task of providing optimal thermal control for both battery cells and passenger cabin, and lacks flexibility in responding to varying ambient conditions and component operating characteristics.
Innovation Solution
A dual mode thermal management system with a first coolant loop for the battery and a second coolant loop for the drive train, utilizing a dual mode valve system that allows the loops to operate either in parallel or series, along with a refrigeration subsystem, heater, and radiator, enabling flexible thermal routing and management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple independent thermal management subsystems are used for battery and drive train cooling, then each component can be cooled independently, but the system complexity increases due to multiple pumps, valves, and components
Solution Approach 1:
The patent merges the battery cooling loop and drive train cooling loop into a single integrated thermal management system that shares common components including pump, radiator, and coolant reservoir. The system uses flow control valves to dynamically route coolant flow to different components, enabling independent thermal control without requiring separate physical subsystems for each component.
2Device complexity
If a single thermal management system with shared coolant loop is used, then system complexity is reduced, but flexibility to respond to varying thermal demands of different components is limited
Solution Approach 1:
The patent implements dynamic flow control using electronically controlled valves that can adjust coolant flow distribution in real-time based on thermal demands. The system transitions from static parallel/series configurations to dynamic flow routing where the valve positions are continuously adjusted according to temperature sensors and control algorithms, enabling flexible response to varying thermal conditions.
Solution Approach 2:
The single coolant loop is designed to serve multiple functions by sequentially or simultaneously cooling different components. The same coolant stream that cools the battery can subsequently cool the drive train motor or pass through the radiator for heat rejection, making the thermal management system multi-functional rather than dedicated to a single component.
3Productivity
If coolant loops are configured in parallel, then each loop operates independently with optimal flow rates, but the system requires additional valves and control mechanisms
Solution Approach 1:
The patent segments the thermal management system into distinct cooling zones (battery cooling section and drive train cooling section) within the single coolant loop. Each zone has dedicated flow control capability through electronically actuated valves that can independently regulate coolant flow rates to match the specific thermal demands of each component while sharing common infrastructure.
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 system enhances efficiency and simplifies thermal management by allowing optimal thermal and performance optimization based on ambient conditions and component needs, reducing complexity and operational costs, and improving energy usage.
Implementation Method 1
a refrigeration subsystem in thermal communication with the first coolant loop, for example using a heat exchanger
Implementation Method 2
a heater in thermal communication with the first coolant loop
Implementation Method 3
The second coolant loop may include a radiator, for example coupled to the second coolant loop using a bypass valve
Implementation Method 4
The second coolant loop may include a radiator, for example coupled to the second coolant loop using a bypass valve
Data Source
AI summary
A dual mode, thermal management system for use in a vehicle is provided. At a minimum, the system includes a first coolant loop in thermal communication with a battery system, a second coolant loop in thermal communication with at least one drive train component (e.g., electric motor, power electronics, inverter), and a dual mode valve system that provides means for selecting between a first mode where the two coolant loops operate in parallel, and a second mode where the two coolant loops operate in series.