Climate-Controlled EV Charging Station for Battery Thermal Load Shifting
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Solution Overview
Problem
The rapid advancement of fast charging technologies for electric vehicles has increased cooling demands during charging, leading to oversized refrigerant systems, efficiency losses, and reduced range, while cold conditions require enhanced battery heating, straining the vehicle's heating system, especially in extreme cold regions.
Innovation Solution
A charging station assembly that generates and delivers conditioned airflow to enhance the thermal management of vehicle batteries by controlling temperature and flow rate based on ambient conditions, directing airflow to the vehicle's outside heat exchanger or battery pack, thereby shifting the thermal load from the vehicle's refrigerant system and eliminating the need for an oversized system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the refrigerant system is upsized to meet fast charging cooling demand, then cooling capacity is improved, but system efficiency deteriorates and packaging constraints worsen
Solution Approach 1:
The patent combines the charging station with a climate control system that includes a refrigerant system, creating an integrated unit that provides both charging and thermal management functions. This merging allows the charging station to directly control and optimize cooling for the battery during charging operations.
Solution Approach 2:
The climate control system is activated before or during the charging process to pre-cool the battery or maintain optimal temperature conditions. This preliminary action ensures the battery is ready to receive high-power charging without thermal issues, avoiding the need for oversized reactive cooling capacity.
2Power
If the refrigerant system is upsized to meet fast charging cooling demand, then cooling capacity is improved, but packaging constraints worsen
Solution Approach 1:
The charging station and climate control system are integrated into a single unified structure, combining functions that were previously separate. This integration eliminates duplicate components and reduces overall system volume while maintaining full cooling capacity for fast charging operations.
3Productivity
If enhanced battery heating is provided in cold conditions, then charging rate is improved, but heating system strain increases
Solution Approach 1:
The charging station integrates a heating system with the charging process, allowing simultaneous charging and battery heating. The climate control system monitors battery temperature and activates heating elements when needed, ensuring optimal charging conditions without overloading the vehicle's separate heating system.
Solution Approach 2:
The integrated heating system activates before charging begins in cold conditions, pre-warming the battery to an optimal temperature range. This preliminary heating reduces the charging rate limitation caused by cold temperatures without requiring excessive energy during the actual charging process.
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
Improves both cooling and heating capacities of vehicle batteries, optimizing thermal management and reducing the strain on the vehicle's systems, while maintaining efficient charging performance across varying ambient conditions.
Implementation Method 1
In cold ambient conditions, the charging station provides hot air to facilitate battery heating
Implementation Method 2
In hot ambient conditions, the charging station provides cool air to facilitate battery cooling
Implementation Method 3
The conditioned airflow may also be routed to the battery pack for direct cooling or heating through additional ventilation system
Implementation Method 4
The conditioned airflow may be directed toward an outside heat exchanger of a refrigerant system of the vehicle to enhance capacity
Data Source
AI summary
A charging station assembly capable of generating and delivering a conditioned airflow while charging a battery of a vehicle. The temperature and flow rate of this conditioned airflow may be controlled based on the ambient conditions and battery status. The conditioned airflow may be directed toward an outside heat exchanger of a refrigerant system of the vehicle to enhance capacity. The conditioned airflow may also be routed to a battery pack for direct cooling or heating through additional ventilation system. In hot ambient conditions, the charging station provides cool air to facilitate battery cooling. In cold ambient conditions, the charging station provides hot air to facilitate battery heating. This charging station assembly shifts the load from the vehicle refrigerant system to the charging system, thereby improving battery thermal management capability, while eliminating the need for an oversized refrigerant system.