EV Cooling Circuit Layout for Continuous Air Bubble Removal
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Solution Overview
Problem
In electric vehicle cooling systems, air bubbles are not efficiently removed from the cooling circuit for the battery when it operates independently of the power electronic module's cooling circuit, leading to reduced cooling efficiency.
Innovation Solution
A continuous reservoir tank is connected to both cooling circuits, allowing air to be removed regardless of the cooling mode, with a mode-switching valve and controller managing coolant flow between the circuits based on temperature to optimize air removal efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the reservoir tank is provided only in the cooling circuit for cooling the PE module, then air bubbles are removed from the PE module cooling circuit, but air bubbles cannot be removed from the battery cooling circuit when it operates independently
Solution Approach 1:
The reservoir tank is designed to serve both the battery cooling circuit and the PE module cooling circuit simultaneously. By positioning the reservoir tank at a location accessible to both circuits and providing multiple air outlet passages, the system enables air removal functionality across multiple cooling modes (independent battery cooling, independent PE cooling, and integrated cooling), making the reservoir tank a universal air removal component for the entire thermal management system.
2Reliability
If the reservoir tank is positioned to serve both cooling circuits, then air removal is enabled in all cooling modes, but the system complexity increases
Solution Approach 1:
The patent merges the air removal functions for both cooling circuits into a single reservoir tank located in the battery cooling circuit. By combining multiple air outlet passages within one reservoir tank and using a unified air outlet, the system eliminates the need for separate air removal devices for each circuit, thereby reducing overall system complexity while maintaining effective air removal across all cooling modes.
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 setup ensures efficient air removal from both cooling circuits in both independent and integrated cooling modes, enhancing overall cooling system performance by maintaining constant air removal regardless of operating conditions.
Implementation Method 1
a reservoir tank, which is continuously connected to the first and second cooling circuits to remove air in the coolant flowing through each of the first and second cooling circuits in the reservoir tank
Implementation Method 2
a first cooling circuit configured to cool a battery by coolant that circulates in accordance with operation of a first circulation pump and exchanges heat with a first heat exchange module
Data Source
AI summary
A cooling system for electric vehicles, which enables air to be efficiently removed from a cooling circuit due to optimal placement of a reservoir tank, includes a first cooling circuit configured to cool a battery by coolant that circulates in accordance with operation of a first circulation pump and exchanges heat with a first heat exchange module, a second cooling circuit configured to cool a PE module using coolant that circulates in accordance with operation of a second circulation pump and exchanges heat with a second heat exchange module, the second cooling circuit being configured so that the coolant in the first cooling circuit circulates through the second cooling circuit, and a reservoir tank, which is continuously connected to the first and second cooling circuits to remove air in the coolant flowing through each of the first and second cooling circuits in the reservoir tank.