Electrode-Based Fluid Heating for Dynamic EV Thermal Management
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Solution Overview
Problem
Existing heating systems for electric vehicles, particularly those with high voltage battery packs, face challenges in dynamically controlling temperature due to thermal inertia and are not suitable for proximity to sensitive components, and can suffer from scale formation issues, leading to inefficiencies and potential damage.
Innovation Solution
A system comprising cells with electrode pairs that heat a fluid by regulating its electrical conductivity and applying appropriate voltage, allowing for dynamic thermal management and compact, lightweight design, suitable for high voltage applications, and preventing scale formation through inert materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional resistive heating elements are used in high voltage applications, then heating capability is provided, but thermal inertia makes dynamic temperature control difficult and the system becomes bulky
Solution Approach 1:
The patent replaces conventional resistive heating elements with electrostatic heating plates that generate electric fields to heat the coolant directly. This substitution eliminates the thermal inertia associated with resistive elements while enabling rapid, dynamic temperature control through electronic field modulation, directly resolving the contradiction between response speed and system complexity.
Solution Approach 2:
The system dynamically adjusts the voltage applied to the electrostatic heating plates based on real-time temperature feedback from sensors. By changing the electrical parameter (voltage) in response to temperature conditions, the system achieves precise dynamic control without thermal inertia, allowing the coolant temperature to be rapidly adjusted according to battery pack requirements.
2Volume of moving object
If conventional heating systems are placed near sensitive components, then space is saved, but overheating risk increases
Solution Approach 1:
By replacing resistive heating elements with electrostatic heating plates, the system generates heat through electric fields rather than hot surfaces. This eliminates the overheating risk to sensitive components while maintaining system compactness, as the heating function is integrated directly into the coolant flow path without requiring physical separation for safety reasons.
Solution Approach 2:
The electrostatic field acts as an intermediary between the power source and the coolant, transferring energy without requiring direct thermal contact or high-temperature surfaces. This allows the heating system to be positioned close to sensitive components without transferring harmful thermal energy, resolving the contradiction between compactness and safety.
3Productivity
If high power density heating is implemented, then heating efficiency improves, but scale formation on heating surfaces occurs
Solution Approach 1:
The patent replaces surface-based resistive heating with volume-based electrostatic heating of the coolant. Since the electric field heats the coolant throughout its volume rather than transferring heat from a surface, there are no heating surfaces for scale to form on, eliminating this harmful effect while maintaining high heating efficiency.
Solution Approach 2:
The electrostatic field serves as an intermediary that transfers energy directly to the coolant molecules without requiring contact with any physical surface. This eliminates the interface between heating element and coolant where scale would normally accumulate, allowing sustained high-power density operation without degradation from scale formation.
4Adaptability or versatility
If 12V/24V battery heating systems are used in high voltage vehicles, then existing heaters can be utilized, but the watt-density is inappropriate for high voltage applications
Solution Approach 1:
The system is designed to operate with the vehicle's high voltage battery (450VDC), utilizing the available electrical parameter directly. By changing the operating voltage parameter from conventional 12V/24V to high voltage, the system achieves appropriate watt-density for rapid heating applications while remaining compatible with the vehicle's electrical architecture through the electrostatic heating mechanism.
Solution Approach 2:
The electrostatic heating plates can be integrated into the existing coolant circulation system of high voltage vehicles, serving multiple functions: heating the coolant for battery thermal management, utilizing high voltage power directly, and providing rapid response heating. This multi-functionality allows the system to adapt to high voltage applications while maintaining compatibility with existing vehicle architectures.
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 provides effective and dynamic thermal management for electric vehicle components, maintaining optimal temperatures and preventing damage from overheating, while being compact and safe for proximity to sensitive components.
Implementation Method 1
determine from the electrical conductivity, or specific conductance, of the fluid a voltage to apply across the one or more electrode pairs to heat the fluid; pass the voltage from the one or more electrode pairs to the fluid to produce a heated fluid
Data Source
AI summary
A system and method for heating a vehicle component is provided and comprises one or more cells for retaining a fluid, each cell including one or more electrode pairs positioned therein. The one or more cells are arranged along a flow path including an inlet to and an outlet from the one or more cells. A controller is provided which is configured to: regulate the flow of the fluid from the inlet to the one or more cells; determine at the one or more cells the electrical conductivity, or specific conductance, of the fluid; determine from the electrical conductivity, or specific conductance, of the fluid a voltage to apply from a high voltage battery, or an external power source located outside of the vehicle, across the one or more electrode pairs at a current sufficient to heat the fluid therein; and pass the current from the one or more electrode pairs to the fluid to produce a heated fluid, wherein the heated fluid transfers heat to one or more vehicle components via the outlet.