EV Battery Thermal Management During Charging

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Solution Overview

Problem

Battery electric vehicles face reduced range and prolonged charging times due to temperature limitations on traction batteries, particularly in cold environments, where battery capacity and charging rates are restricted.

Innovation Solution

A thermal management system with a controller that prioritizes heating the lowest temperature cell while charging, using a portion of the charger's power for heating and another for charging, optimizing energy distribution to maximize battery capacity and charging rate.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the battery is charged at a high rate, then the charging time is reduced, but the battery temperature decreases and charging capacity is restricted

Engineering Contradiction:

Improvecharging rateVSAvoidbattery temperature

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The patent converts the harmful effect of low battery temperature (which restricts charging rate) into a beneficial heating mechanism by diverting a portion of the charging power to heat the battery. The controller dynamically adjusts the heating power based on temperature feedback, transforming the temperature problem into a solution that enables higher charging rates while maintaining optimal temperature.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent implements dynamic control of the charging system by continuously monitoring battery temperature and adjusting the division of charging power between heating and charging functions. The controller modifies the heating power proportion based on real-time temperature feedback, creating a dynamic balance that adapts to changing battery conditions during the charging process.

Inventive Principle:

Principle #15Dynamics

2Productivity

If the battery is heated using a portion of charging power, then the battery temperature increases and charging capacity improves, but the actual charging energy is reduced

Engineering Contradiction:

Improvecharging capacityVSAvoidcharging energy

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The patent employs feedback control by continuously monitoring battery temperature and using this information to dynamically adjust the heating power proportion. The controller receives temperature feedback from the battery and modifies the heating charge proportion accordingly, ensuring that heating is applied only when necessary and at the optimal level to maintain charging capacity while minimizing energy diverted from charging.

Inventive Principle:

Principle #23Feedback

3Productivity

If the battery temperature is maintained at optimal level, then the battery capacity and charging rate are maximized, but additional heating energy is required

Engineering Contradiction:

Improvecharging rateVSAvoidheating energy

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The patent makes the charging system multi-functional by enabling it to perform both heating and charging functions simultaneously through a single charging interface. The controller dynamically allocates the incoming charging power between heating the battery and charging the battery, eliminating the need for separate heating systems and external energy sources while maximizing the utilization of available charging energy.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 approach ensures efficient charging and heating of traction batteries, enhancing vehicle performance by maintaining optimal battery health and capacity, thereby meeting user expectations even in cold conditions.

Implementation Method 1

The thermal circuit has a thermal source and a thermal sink... heat the traction battery if the lowest temperature cell is below a predetermined temperature

Methodology Applied

Scientific EffectThermal energy transfer: Conduction (thermal)

Implementation Method 2

charge the traction battery using a maximum charging current based on the lowest temperature cell while the traction battery is connected to a charger and external power source

Methodology Applied

Scientific EffectElectrical charging: Battery (electricity)

Data Source

PatentUS9337680B2Method and system for controlling an electric vehicle while charging

Publication Date: 2016.05.10 FORD GLOBAL TECH LLC

AI summary

A vehicle includes a traction battery having a thermal circuit, and a controller. The controller is configured to: (i) charge the traction battery using a maximum charging current defined by the lowest temperature cell while the traction battery is connected to the charger, and (ii) heat the traction battery if the lowest temperature cell is below a predetermined temperature while the traction battery is charging. A method for controlling an electric vehicle while connected to a charger includes charging the battery using a first portion of power from the charger while heating the battery using a second portion of power from the charger in response to a low cell temperature in a traction battery.