EV Coolant Loop Layout for Flexible Thermal Routing
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Solution Overview
Problem
Existing coolant systems for electric and hybrid vehicles are complex and costly, with multiple components and valves, limiting flexibility and efficiency in thermal management.
Innovation Solution
A simplified coolant system design with a single fluidically continuous coolant line connecting the first and third paths to an air/coolant heat exchanger and a valve system, allowing flexible coolant flow direction and reduced component count, including a single coolant tank for storage and pressure equalization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a traditional coolant system with multiple separate coolant paths and components is used, then thermal management coverage is comprehensive, but system complexity and cost increase
Solution Approach 1:
The patent merges multiple separate coolant paths into a single fluidically continuous coolant line that serves multiple components (battery, drivetrain, heat pump) through strategic placement of heat exchangers and valves. This consolidation reduces the number of separate cooling circuits while maintaining the ability to independently manage thermal requirements of different components, directly addressing the contradiction between system complexity and thermal management versatility.
Solution Approach 2:
The single coolant line is designed to serve multiple functions by integrating various heat exchangers (air/coolant heat exchanger, coolant/refrigerant heat exchanger) and components along its path. The same coolant stream can simultaneously cool the battery, cool the drivetrain, or serve as a heat source for the heat pump, depending on valve configuration. This multi-functionality approach reduces system complexity while preserving adaptability across different operating conditions.
2Device complexity
If multiple valves and components are used to control coolant flow, then coolant distribution control is precise, but system cost and complexity increase
Solution Approach 1:
The patent combines multiple valve functions into a single multi-position valve that can direct coolant flow to different destinations (air/coolant heat exchanger, coolant/refrigerant heat exchanger, or bypass) and control flow direction within the single coolant line. This consolidation of valve functions reduces the total number of valves from multiple separate control devices to one integrated control element, simplifying the system while maintaining precise flow distribution control.
3Device complexity
If a reduced refrigerant system is used, then system cost is reduced, but heat exchange capability may be limited
Solution Approach 1:
The patent introduces a coolant/refrigerant heat exchanger as an intermediary device that enables thermal energy transfer between the simplified refrigerant system and the coolant system. This heat exchanger acts as a mediator, allowing the reduced refrigerant system to still provide effective cooling by transferring heat from the coolant stream to the refrigerant cycle, thereby maintaining heat exchange capability while keeping the refrigerant system compact and cost-effective.
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 thermal management with reduced complexity and cost, allowing broad flexibility in component selection and operation, while minimizing the refrigerant system to a necessary minimum.
Implementation Method 1
a third coolant path (14) with a coolant/refrigerant heat exchanger (16) for the purpose of transmitting heat between the coolant system and a refrigerant system of the vehicle
Implementation Method 2
an air/coolant heat exchanger (18) for the purpose of transmitting heat between the coolant and ambient air in a free environment
Data Source
AI summary
A coolant system for circulating a coolant for an electric or hybrid vehicle, having a first coolant path with at least one first component to be cooled and/or to be heated, a second coolant path with at least one second component to be cooled and/or to be heated, and a third coolant path with a coolant/refrigerant heat exchanger for transmitting heat between the coolant system and a refrigerant system of the vehicle. An air/coolant heat exchanger transmits heat between the coolant and ambient air in a free environment. A valve system for realizing a plurality of coolant system states of the coolant system. The first coolant path with the aforementioned first component and the third coolant path with the coolant/refrigerant heat exchanger firstly have a common coolant-conducting connection to the air/coolant heat exchanger and secondly a common coolant-conducting connection to the valve system.