EV Fast Charging Heat Exchanger for Battery Thermal Management
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Solution Overview
Problem
The existing HVAC systems in electric vehicles face challenges in cooling batteries during fast charging sessions, leading to increased noise, vibration, and harshness, as well as reduced cooling capacity for passenger comfort, due to the compressor operating at maximum capacity and decreased refrigerant cooling efficiency.
Innovation Solution
A battery coolant circuit with a charging heat exchanger that allows for selective fluid and heat exchange communication with a charging coolant from an external charging station, enabling efficient heat transfer and reducing the need for the HVAC system to operate at maximum capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the compressor operates at maximum capacity to cool the battery during fast charging, then the battery cooling capacity is improved, but noise, vibration, and harshness increase significantly
Solution Approach 1:
The cooling system is segmented into two independent circuits: a refrigerant circuit for HVAC and a battery coolant circuit for thermal management. This allows the battery cooling function to be separated from the compressor-driven refrigerant system, enabling battery cooling without requiring the compressor to operate at maximum capacity, thereby reducing NVH.
Solution Approach 2:
A charging heat exchanger serves as an intermediary component that enables heat transfer from the battery coolant to an external charging coolant. This intermediary mechanism provides an alternative heat rejection path that does not depend on the compressor, allowing effective battery cooling with reduced compressor workload and associated NVH.
2Temperature
If the compressor operates at maximum capacity to cool the battery, then the battery cooling performance is improved, but the durability of the compressor is compromised
Solution Approach 1:
The cooling system is segmented into two independent circuits: a refrigerant circuit for HVAC and a battery coolant circuit for thermal management. This allows the battery cooling function to be separated from the compressor-driven refrigerant system, enabling battery cooling without requiring the compressor to operate at maximum capacity, thereby reducing NVH.
Solution Approach 2:
A charging heat exchanger serves as an intermediary component that enables heat transfer from the battery coolant to an external charging coolant. This intermediary mechanism provides an alternative heat rejection path that does not depend on the compressor, allowing effective battery cooling with reduced compressor workload and associated NVH.
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 solution effectively cools the battery during fast charging sessions without excessive HVAC system strain, maintaining passenger comfort and extending compressor durability by utilizing a higher cooling capacity than traditional refrigerant circuits.
Implementation Method 1
a charging heat exchanger in heat exchange relationship with a charging coolant originating from a charging station for cooling the battery during a fast charging process
Implementation Method 2
The chiller may be in fluid and heat exchange relationship with the coolant of the coolant circuit to allow the heat of the battery to be rejected to the refrigerant within the chiller
Data Source
AI summary
A charging system includes an electric vehicle having a battery coolant circuit including a charging heat exchanger and a battery as well as a charging station including a charging coolant and a cooling heat exchanger for cooling the charging coolant. The charging coolant is selectively placed in fluid communication and heat exchange communication with the charging heat exchanger of the electric vehicle. The charging heat exchanger is disposed on a charging coolant flow path formed in the electric vehicle that extends from an inlet port configured for coupling to an inlet fitting of the charging station to an outlet port configured for coupling to an outlet fitting of the charging station.