EV Thermal Management Module With Reversed Coolant Flow

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Solution Overview

Problem

Existing cooling systems in electric vehicles are inadequate for quick charging processes, particularly in high ambient temperatures, leading to overheating of batteries and reduced performance due to insufficient heat dissipation.

Innovation Solution

A thermal management module with a regulator to control coolant flow through heat sinks, including the option to reverse coolant flow direction and utilize components like electric motors as passive heat sinks during charging, enhancing heat dissipation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a conventional cooling system is used during quick charging, then the battery can be charged quickly, but the battery overheats and performance is reduced

Engineering Contradiction:

Improvecharging speedVSAvoidbattery temperature

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The patent reverses the normal coolant flow direction during quick charging operations. Instead of coolant flowing from the battery to the heat sink, it flows from the heat sink to the battery, pre-cooling the coolant before it contacts the battery. This inverted flow pattern enables effective heat removal during high-power charging without compromising charging speed.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The system pre-cools the coolant by circulating it through the heat sink before the coolant reaches the battery during quick charging. This preliminary cooling action ensures that the coolant enters the battery at a lower temperature, maximizing its heat absorption capacity and preventing battery overheating before it occurs.

Inventive Principle:

Principle #10Preliminary action

2Temperature

If coolant flow is increased to cool the battery, then heat dissipation improves, but energy consumption increases

Engineering Contradiction:

Improvebattery temperatureVSAvoidenergy consumption

Core Design Contradiction:

TemperatureVSUse of energy by moving object

Solution Approach 1:

The patent employs dynamic flow regulation through electronically controlled valves that adjust coolant flow rates based on real-time battery temperature, state of charge, and charging power levels. This dynamic adaptation optimizes cooling efficiency while minimizing unnecessary energy consumption during different charging phases and temperature conditions.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes multiple parameters including coolant flow rate, flow direction, and heat sink activation status based on charging conditions. By dynamically adjusting these parameters, the system achieves effective battery temperature control while optimizing energy consumption across different operating scenarios.

Inventive Principle:

Principle #35Parameter changes

3Temperature

If a complex thermal management system is implemented, then cooling performance improves, but device complexity increases

Engineering Contradiction:

Improvebattery temperatureVSAvoidsystem complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent makes the cooling system multi-functional by enabling it to operate in both normal cooling mode and quick charging cooling mode with reversed flow direction. The same coolant circulation system, heat sink, and control mechanisms serve dual purposes: standard thermal management during normal operation and enhanced active cooling during quick charging, eliminating the need for separate dedicated cooling systems.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system merges the quick charging cooling function into the existing thermal management infrastructure by integrating reversed flow capability into the conventional coolant circulation system. This consolidation allows effective quick charging cooling without adding entirely separate systems, thereby limiting the increase in overall device complexity.

Inventive Principle:

Principle #5Merging (Combining)

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

The solution effectively prevents battery overheating and maintains performance during quick charging by efficiently dissipating heat, reducing charging time and protecting temperature-sensitive components.

Implementation Method 1

a cooling circuit or coolant circuit for an electric vehicle that regulates or controls the flow of a coolant through the circuit

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

at least one heat sink, wherein the at least one regulator is designed to activate the at least one heat sink

Methodology Applied

Scientific EffectThermal radiation: Thermal Radiation

Implementation Method 3

The thermal management module improves and shortens the charging process

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS20250249775A1Thermal Management Module for an Electric Vehicle

Publication Date: 2025.08.07 MAHLE INT GMBH

AI summary

A thermal management module for an electric vehicle is provided. The thermal management module can be placed in a cooling circuit in an electric vehicle, and wherein the thermal management module is designed to regulate or control the flow of a coolant in the cooling circuit. The thermal management module contains at least one regulator, wherein the at least one regulator is designed to regulate or control the flow of the coolant through at least one heat sink.