External Thermal Conditioning for EV Battery Fast Charging
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Solution Overview
Problem
Fast charging of electric vehicles is limited by battery temperature, especially in cold environments, where preheating is necessary, and existing external thermal conditioning systems are costly and difficult to install.
Innovation Solution
A method involving a charging station with a compact external thermal conditioning system using a coolant tank and heat pump to manage battery temperature during charging, providing high power input during peak charging and cooling during subsequent lower power phases, with a cooling medium capable of removing excess heat efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If an external thermal conditioning system with hot and cold reservoirs is provided to manage battery temperature during fast charging, then battery temperature control is improved, but system cost and installation complexity increase
Solution Approach 1:
The patent combines the cooling reservoir, heating reservoir, and heat pump into a single integrated external thermal conditioning system. The cooling reservoir and heating reservoir are merged with the heat pump to form a compact unit that provides both cooling and heating functions, reducing the number of separate components and simplifying installation while maintaining effective battery temperature control
Solution Approach 2:
The external thermal conditioning system is designed to perform multiple functions: the cooling reservoir provides cooling during fast charging, the heating reservoir provides preheating in cold environments, and the heat pump enables heat transfer between the two reservoirs. This multi-functional design eliminates the need for separate cooling and heating systems, reducing overall system complexity and cost
2Productivity
If high power input is supplied during peak charging time to achieve fast charging, then charging speed is improved, but battery temperature rises excessively
Solution Approach 1:
The system performs preliminary cooling by storing cold energy in the cooling reservoir before fast charging begins. During peak charging power input, the pre-cooled reservoir immediately absorbs the heat generated by the battery, preventing excessive temperature rise and enabling sustained high-power charging without thermal limitations
Solution Approach 2:
The cooling medium in the cooling reservoir undergoes phase change or temperature variation to absorb large amounts of heat during fast charging. The reservoir is designed to handle the thermal load through controlled temperature changes of the cooling medium, efficiently managing the heat generated during high-power charging intervals
3Power
If a cooling reservoir with sufficient cooling capacity is provided to manage heat during fast charging, then cooling effectiveness is improved, but system size and installation difficulty increase
Solution Approach 1:
The system achieves high cooling power in a compact size by changing the parameters of the cooling medium, such as using substances with high specific heat capacity or phase change properties. The cooling reservoir is designed with optimized volume and thermal properties to provide sufficient cooling capacity without requiring large physical dimensions, making it suitable for installation at standard charging locations
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
Enables efficient fast charging of electric vehicles by effectively managing battery temperature, reducing installation costs, and maintaining efficient cooling with minimal power usage, suitable for various climates and battery sizes.
Implementation Method 1
supplying a cooling medium from a coolant tank of the external cooling unit to the vehicle while providing a high level power input via the power cable during a peak charging time interval
Implementation Method 2
supplying a cooling medium via a heat pump to the heat exchange connector while providing a second level power input via the power cable
Implementation Method 3
After completion of one or more charging cycles, the cooling medium in the coolant tank can be cooled by the heat pump to regain its low cooling temperature
Data Source
Figure 1~2
AI summary
The invention relates to a method of charging an electric vehicle (3), comprising: - providing an external charging unit (5) and an external cooling unit (7), - connecting a battery power inlet (27) on the vehicle (3) to the charging unit (5) via a power cable (25), - connecting a heat exchange connector (20,21) of a heat exchanger (22) of the vehicle (3) to the external cooling unit (7) via a heat exchange duct (15,16), - supplying a cooling medium from a coolant tank (9) of the external cooling unit (7) to the vehicle (3) while providing a high level power input via the power cable (25) during a peak charging time interval tpc, and - supplying a cooling medium from a heat pump (10) to the heat exchange connector (20,21) while providing a second level power input via the power cable (25), that is lower than the first level during a subsequent charging time interval tsc following on the peak charging time interval.