EV Thermal Fluid Routing for Cabin and Battery Heating
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Solution Overview
Problem
Existing thermal management systems in electric vehicles are inefficient in using excess heat from the cooling loop for heating the cabin and energy storage system, leading to increased energy consumption and reduced battery lifespan.
Innovation Solution
A thermal management system that includes a heat exchanger, a heater, and a control unit to utilize excess heat from the cooling loop for both cabin and energy storage heating, with valves and sensors to manage thermal fluid distribution based on temperature data, minimizing the need for additional heaters and optimizing energy use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate heating systems are used for cabin and energy storage system, then heating function is reliable, but device complexity and weight increase
Solution Approach 1:
The patent combines the cabin heating function and energy storage system heating function into a single integrated thermal management system. One heater can selectively heat either the cabin or the energy storage system based on control signals, eliminating the need for separate heating systems and reducing overall system complexity and weight while maintaining reliable heating capability for both functions.
Solution Approach 2:
The heater is designed as a multi-functional component that can serve multiple purposes: heating the cabin during cold weather and heating the energy storage system when battery temperature drops below optimal operating range. The control unit enables the heater to switch between these functions based on real-time temperature monitoring and system requirements.
2Reliability
If separate heaters are used for cabin and energy storage system, then heating reliability is ensured, but weight increases
Solution Approach 1:
The patent merges the heating functions for the cabin and energy storage system into a single physical heater unit. This consolidation eliminates redundant heating components, reducing the overall weight of the thermal management system while maintaining the ability to provide reliable heating to both the cabin and battery as needed.
3Ease of operation
If excess heat from cooling loop is not utilized, then system operation is simple, but energy consumption increases
Solution Approach 1:
The patent converts the waste heat from the cooling loop into a useful resource for heating the cabin or energy storage system. When the vehicle cooling system generates excess heat, the control unit redirects this thermal energy through the heater to provide cabin heating or battery thermal management, transforming what would otherwise be wasted energy into a beneficial heating source and reducing overall energy consumption.
Solution Approach 2:
The thermal management system utilizes its own internally generated waste heat from the cooling loop to meet heating demands, rather than requiring entirely separate heating sources. This self-service approach allows the system to recycle its thermal byproducts, reducing external energy requirements while maintaining simple operation through integrated control.
4Reliability
If multiple heaters are used for cabin and energy storage heating, then heating reliability is improved, but cost increases
Solution Approach 1:
The patent consolidates the heating functions for both cabin and energy storage system into a single heater unit, reducing the total number of heating components required. This merger lowers manufacturing costs by eliminating redundant parts while maintaining heating reliability through intelligent control that directs the single heater to serve whichever system requires heating at any given time.
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 reduces energy consumption from the energy storage system for heating, prolongs battery life, and minimizes weight and cost by using a single heater for both cabin and energy storage heating, while optimizing thermal fluid distribution.
Implementation Method 1
one heat exchanger arranged to heat the energy storage system
Implementation Method 2
one heater arranged to heat the cabin and to provide heat to the heat exchanger
Implementation Method 3
a cooling loop including a thermal fluid for cooling the vehicle component
Data Source
AI summary
A thermal management system for controlling the temperature in a cabin and an energy storage system of an electric vehicle including a vehicle component is provided. The system provides for a heat exchanger arranged to heat the energy storage system, a heater for heating the cabin and the heat exchanger, a first valve arranged to receive a fluid that has been used for cooling the vehicle component, and to provide fluid to the heater, a temperature sensor arranged to measure the temperature of the fluid entering the first valve, a second valve receiving the fluid from the heater and having a first outlet in fluid communication with the cabin, and a second outlet in fluid communication with the heat exchanger, and a control unit.