EV Module Cooling Channels Using Phase-Change Refrigerant
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Solution Overview
Problem
Current thermal management systems for electric vehicles rely on liquid coolants, which have low specific heat absorption capacity, high viscosity, and high inertia, leading to inefficient heat transfer and increased energy consumption due to the need for high mass flow rates and pump energy expenditure.
Innovation Solution
A thermal management system that uses a refrigerant changing phases from liquid to gas as it flows through cooling channels, reducing viscosity and inertia, allowing for lower mass flow rates and lower energy consumption through a compressor, enhancing thermal and mechanical efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If liquid coolant is used for thermal management, then the system can cool modules effectively, but the specific heat absorption capacity per unit mass is low and energy consumption is high
Solution Approach 1:
The patent changes the physical state parameter of the cooling medium from liquid to gas (refrigerant). This parameter change enables the refrigerant to undergo phase transition during cooling, dramatically increasing its specific heat absorption capacity per unit mass and reducing the energy required for thermal management.
Solution Approach 2:
The patent utilizes phase transition of the refrigerant from liquid to gas as it flows through the cooling channels. This phase transition absorbs significant heat from the modules, providing efficient cooling with lower mass flow rates and reduced energy consumption compared to liquid coolant systems.
2Temperature
If liquid coolant is circulated through cooling channels, then heat transfer occurs, but the viscosity and inertia are high requiring high mass flow rates
Solution Approach 1:
The patent changes the physical state parameter of the cooling medium from liquid to gas (refrigerant). This parameter change enables the refrigerant to undergo phase transition during cooling, dramatically increasing its specific heat absorption capacity per unit mass and reducing the energy required for thermal management.
Solution Approach 2:
The patent utilizes phase transition of the refrigerant from liquid to gas as it flows through the cooling channels. This phase transition absorbs significant heat from the modules, providing efficient cooling with lower mass flow rates and reduced energy consumption compared to liquid coolant systems.
3Temperature
If high-speed cooling air is directed towards radiator by cooling fan, then liquid coolant is cooled effectively, but energy consumption increases
Solution Approach 1:
The patent utilizes phase transition of the refrigerant from liquid to gas as it flows through the cooling channels. This phase transition absorbs significant heat from the modules, providing efficient cooling with lower mass flow rates and reduced energy consumption compared to liquid coolant systems.
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 system achieves improved thermal management efficiency by utilizing a refrigerant with higher specific heat absorption capacity, reducing energy requirements and enhancing cooling performance with lower mass flow rates and viscosity, thus optimizing energy use and cooling effectiveness.
Implementation Method 1
the refrigerant that is received in the substantially liquid state flows through the at least one cooling channel and changes its state to a substantially gaseous state while absorbing heat from the module
Implementation Method 2
the refrigerant that is received in the substantially liquid state flows through the at least one cooling channel and changes its state to a substantially gaseous state while absorbing heat from the module
Implementation Method 3
the compressor compresses the refrigerant that is received in the compressor
Implementation Method 4
the condenser dissipates heat from the refrigerant that is received in the condenser
Implementation Method 5
the expansion valve controls a flow of refrigerant that flows through the outlet of the condenser to the inlet of the at least one cooling channel
Data Source
AI summary
A thermal management system for at least one module of an electrically powered vehicle is disclosed. The thermal management system comprises at least one cooling channel defined within the at least one module and receives a refrigerant therein for cooling the at least one module. A compressor is in flow communication with an outlet of the at least one cooling channel and compresses the refrigerant received from the at least one cooling channel. A condenser is in flow communication with an outlet of the compressor and discharges heat from the refrigerant received from the compressor. An expansion valve is in flow communication with an outlet of the condenser at its inlet and in flow communication with an inlet of the at least one cooling channel at its outlet. The expansion valve controls a flow of refrigerant from the condenser to the at least one cooling channel is also disclosed.