EV Two-Phase Cooling Pre-Loading for Uniform Refrigerant Distribution
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Solution Overview
Problem
Existing cooling systems for electric vehicles, including refrigerant-based systems, suffer from low controllability and inefficiency, leading to increased power consumption and reduced vehicle range due to non-uniform refrigerant distribution and slow reaction times.
Innovation Solution
A pre-loading system that uses a compressor to liquidify refrigerant when the vehicle is connected to an external power source, allowing controlled distribution of liquid refrigerant to various locations within the vehicle, thereby optimizing refrigerant usage and reducing battery power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the compressor is continuously operated to maintain uniform refrigerant distribution, then cooling reliability is improved, but battery power consumption increases
Solution Approach 1:
The system pre-loads liquid refrigerant into the separator and reservoirs when the vehicle is connected to an external power source (plug-in charging). This preliminary action ensures sufficient liquid refrigerant is available before driving, eliminating the need for continuous compressor operation during normal driving to maintain refrigerant distribution, thus reducing battery power consumption while maintaining cooling reliability.
2Stability of the object's composition
If the compressor is operated frequently to redistribute refrigerant, then refrigerant distribution uniformity is improved, but vehicle range decreases
Solution Approach 1:
The system performs preliminary refrigerant distribution by loading liquid refrigerant into the separator and reservoirs during plug-in charging. This ensures uniform refrigerant distribution is achieved before driving, eliminating the need for frequent compressor operations during driving that would consume battery power and reduce vehicle range.
Solution Approach 2:
The system divides the refrigerant storage into multiple segments (separator and reservoirs) that can be independently filled with liquid refrigerant. This segmentation allows efficient storage and distribution of refrigerant without requiring continuous compressor operation, thereby extending vehicle range while maintaining refrigerant distribution uniformity.
3Adaptability or versatility
If a traditional cooling system with dedicated heat exchangers is used, then cooling coverage is improved, but system complexity increases
Solution Approach 1:
The system uses a single two-phase cooling system with a separator and reservoirs that serves multiple cooling functions for different vehicle components (battery, motor, power electronics). By using liquid refrigerant that can be dynamically distributed to various locations, the system achieves versatile cooling coverage without requiring separate dedicated heat exchangers for each component, thus reducing system complexity.
Solution Approach 2:
The system employs dynamic control of liquid refrigerant distribution to adapt cooling capacity to different thermal demands of various components. The controller can selectively supply liquid refrigerant to different locations based on real-time cooling requirements, providing adaptable cooling coverage without the need for complex fixed infrastructure.
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 enhances the controllability of the cooling system, reducing power consumption and increasing the vehicle's range by ensuring efficient refrigerant distribution and dynamic cooling adjustments.
Implementation Method 1
the compressor is active while the vehicle is electrically coupled to the power grid to allow the refrigerant to be liquidified
Implementation Method 2
The refrigerant changes between a liquid phase and a gas phase during the process
Implementation Method 3
a condenser... The liquid refrigerant is accumulated in liquid/vapor separators or reservoirs
Implementation Method 4
The liquid refrigerant is accumulated in liquid/vapor separators or reservoirs
Implementation Method 5
Heat is removed from the hot elements via the latent heat of vaporization of the boiled refrigerant
Implementation Method 6
The liquid refrigerant is then pumped through the heat exchanger to cool the main system components
Data Source
AI summary
A cooling system for an electric vehicle includes a cooling system loop including a refrigerant, a compressor, and a condenser. The cooling system loop is configured to receive the refrigerant after the refrigerant exits the condenser. The cooling system loop comprises a separator configured to receive liquid refrigerant and a component located downstream from the separator. A vehicle plug monitor circuit generates a plug monitor signal when the vehicle is coupled to an external power source. A controller operates the compressor in response to the plug monitor signal to communicate liquid refrigerant to the separator.