Integrated EV Thermal Circuit With Single-Valve Chiller Control
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Solution Overview
Problem
Existing thermal management systems for electric vehicles complicate coolant control by using separate valves for battery-cooling and electric component-cooling circuits, increasing the number of parts and complexity.
Innovation Solution
An integrated thermal management circuit that uses a single control valve to manage the flow of coolant between an electric component line, a battery line, and a refrigerant line, allowing for simultaneous control of coolant flow between the electric component line and the battery line through a chiller, reducing the number of parts and simplifying the system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate valves are used for battery-cooling circuit and electric component-cooling circuit, then each circuit can be controlled independently, but the number of parts increases and control becomes complicated
Solution Approach 1:
The patent merges the battery-cooling circuit and electric component-cooling circuit into a single integrated thermal management circuit. The integration line combines coolant flow from both circuits, and a single control valve at the branch point regulates coolant distribution to both the chiller and radiators, eliminating the need for separate valves while maintaining independent control capability through strategic valve positioning.
Solution Approach 2:
The single control valve positioned at the branch point of the integration line serves multiple functions: it controls coolant flow to the chiller for waste heat recovery, regulates flow to radiators for cooling, and manages the integrated thermal management for both battery and electric components. This multi-functional valve reduces part count while maintaining system versatility.
2Reliability
If multiple separate cooling circuits are used, then each component can be cooled independently, but space utilization and packaging efficiency decrease
Solution Approach 1:
The patent combines multiple cooling circuits into a single integrated circuit where coolant flows through an integration line that merges battery line and electric component line. This consolidation reduces the overall system volume and improves packaging efficiency while maintaining the ability to independently cool each component through the control valve's strategic positioning.
Solution Approach 2:
The integrated thermal management circuit serves multiple cooling functions through a unified structure. The single circuit design with integration line and strategically positioned control valve enables space-efficient packaging while providing independent cooling control for battery, electric components, and chiller operations.
3Measurement precision
If separate cooling circuits with multiple valves are used, then control precision is maintained, but manufacturing cost increases
Solution Approach 1:
The patent merges multiple valve functions into a single control valve positioned at the integration line branch point. This consolidation reduces manufacturing costs by eliminating redundant valves while maintaining coolant flow control precision through the strategic placement of the single valve, which regulates flow to both chiller and radiators effectively.
Solution Approach 2:
The single control valve performs multiple control functions that would traditionally require separate valves. By positioning the valve at the branch point of the integration line, it precisely controls coolant distribution to the chiller and radiators, maintaining measurement and control precision while significantly reducing manufacturing complexity and cost.
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 enables selective recovery of waste heat from both electric components and high voltage batteries with a single chiller, improving space utilization, packaging efficiency, and reducing manufacturing costs.
Implementation Method 1
a chiller connected to the integration line and the refrigerant line so that the coolant from the electric component line or the battery line and the refrigerant from the refrigerant line exchange heat with each other
Implementation Method 2
an electrical component line in which coolant flowing therein heat-exchanges with electrical components and having a first radiator
Implementation Method 3
a battery line in which coolant flowing therein heat-exchanges with a high voltage battery and having a second radiator
Data Source
AI summary
An integrated thermal management circuit for a vehicle includes an electrical component line having a first radiator, a battery line having a second radiator, an integration line branching from the electrical component line and the battery line and joined to the electrical component line and the battery line, a refrigerant line having a cooling core and in which a refrigerant flows, a chiller connected to the integration line and the refrigerant line, and a control valve provided to control a flow of coolant from the integration line through the chiller.