EV Thermal Loop Assembly for Independent Battery and Cabin Control
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Solution Overview
Problem
Current electric vehicles have limited thermal management capabilities, often requiring complex and costly systems that cannot efficiently heat or cool individual components, leading to conflicts between passenger comfort and battery safety, and lack flexibility in temperature control.
Innovation Solution
A thermal management system with a compressor, water-cooled condenser, battery chiller, and valve body assembly that allows separate loops for passenger compartment refrigeration, heating, battery refrigeration, and electrical driver cooling, enabling flexible temperature control and reduced component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If complex pipeline routes and many components are used to form thermal management system, then thermal management coverage is improved, but device complexity and cost increase
Solution Approach 1:
The patent implements a multi-functional thermal management system where a single integrated controller can selectively control heating or cooling of different components (battery, electrical driver, passenger compartment) using shared thermal management components. The system achieves multiple temperature modes through intelligent control strategies that route thermal energy to different targets based on real-time temperature requirements, eliminating the need for separate dedicated systems for each component.
2Adaptability or versatility
If multiple components and complex pipelines are used, then thermal management capability is improved, but manufacturing cost increases
Solution Approach 1:
The patent employs universal thermal management components that can serve multiple functions. A single heating system and a single cooling system are designed to accommodate different components (battery, electrical driver, passenger compartment) through selective activation and intelligent routing, rather than requiring separate dedicated systems for each component. This significantly reduces the total number of components and manufacturing costs.
Solution Approach 2:
The patent merges the heating and cooling control functions into unified systems. The heating system can selectively heat any target component, and the cooling system can selectively cool any target component, by combining control logic and sharing physical infrastructure. This consolidation reduces component count and simplifies manufacturing processes.
3Device complexity
If all components are heated simultaneously, then thermal management is simplified, but user comfort and battery safety requirements cannot be met separately
Solution Approach 1:
The patent implements dynamic control of thermal management systems where the heating or cooling of different components can be independently adjusted based on real-time requirements. The controller monitors temperature conditions of the battery, electrical driver, and passenger compartment, and dynamically activates or deactivates heating/cooling for each component as needed, rather than using fixed simultaneous control modes.
Solution Approach 2:
The patent segments the thermal management control into independent controllable units for different components (battery heating control, electrical driver heating control, passenger compartment heating control). Each component can be controlled independently through selective activation of heating or cooling functions, allowing customized temperature management for each component based on its specific requirements.
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 efficient and flexible temperature control of multiple components, reducing costs and complexity while improving user experience by allowing independent or simultaneous heating/cooling of the passenger compartment, battery, and electrical driver.
Implementation Method 1
a compressor, a water-cooled condenser
Implementation Method 2
a water-cooled condenser includes a first heat exchange pipe and a second heat exchange pipe
Implementation Method 3
a water-cooled condenser
Implementation Method 4
the battery chiller includes a third heat exchange pipe and a fourth heat exchange pipe
Implementation Method 5
an evaporator in an air conditioner box in a passenger compartment
Implementation Method 6
an output end of the compressor is separately connected to an input end of the evaporator
Implementation Method 7
a heater core in the air conditioner box in the passenger compartment
Data Source
AI summary
A thermal management system includes a compressor, a water-cooled condenser, a battery chiller, a valve body assembly, a first water pump, a second water pump, and a third water pump that are disposed in a centralized manner. The thermal management system can separately form a passenger compartment cooling loop, a passenger compartment heating loop, a battery cooling loop, a battery heating loop, and an electrical driver cooling loop, and any one or more of the passenger compartment, the battery, and the electrical driver can be cooled or heated.