EV Thermal Loop Heat Reuse for Cabin and Battery Heating
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Solution Overview
Problem
Current thermal management systems in electric vehicles are inefficient in utilizing 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 redirect excess thermal fluid from the cooling loop to either the cabin or energy storage system, minimizing the need for additional heating and optimizing energy usage by prioritizing heating demands based on temperature data from sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate heating systems are used for the cabin and energy storage system, then heating functionality is ensured, but system weight and cost increase
Solution Approach 1:
The patent combines the heating functions for the cabin and energy storage system into a single integrated heater. The heater can selectively heat either the cabin air or the thermal fluid that circulates through the energy storage system, eliminating the need for separate heating systems and reducing overall system weight and cost.
Solution Approach 2:
The single heater is designed with multi-functionality to perform both cabin heating and energy storage system heating. Through a control system and valve mechanism, the heater can direct thermal energy to different targets based on operational requirements, ensuring reliable heating functionality while minimizing system complexity.
2Loss of energy
If excess heat from the cooling loop is not utilized, then system complexity is reduced, but energy consumption increases
Solution Approach 1:
The patent converts the excess heat from the cooling loop, which would otherwise be wasted energy, into a useful heating resource. The system captures thermal energy from the coolant after it has cooled the energy storage system and redirects it to heat the cabin or supplement heating of the energy storage system, thereby reducing overall energy consumption and improving efficiency.
3Ease of operation
If the thermal management system prioritizes cabin heating, then passenger comfort is improved, but energy storage system temperature control may be compromised
Solution Approach 1:
The patent implements a dynamic control system that can adjust the distribution of thermal energy in real-time based on the operational state of the vehicle and the temperature requirements of both the cabin and energy storage system. The control unit monitors temperatures and actively manages heat distribution, allowing the system to prioritize cabin heating when needed while ensuring the energy storage system remains within acceptable temperature ranges.
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 reduces energy consumption from the energy storage system for heating, prolongs battery life, and minimizes system weight and cost by using a single heater for both cabin and energy storage heating, while optimizing energy 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
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a thermal management system (1) for controlling the temperature in a cabin (2) and an energy storage system (3) of an electric vehicle including a vehicle component (4). The invention also relates to a vehicle including the system (1). The system (1) comprises a heat exchanger (5) arranged to heat the energy storage system (3), a heater (6) for heating the cabin (2) and the heat exchanger (5), a first valve (7) arranged to receive a fluid that has been used for cooling the vehicle component (4), and to provide fluid to the heater (6), a temperature sensor (8) arranged to measure the temperature of the fluid entering the first valve, a second valve (11) receiving the fluid from the heater and having a first outlet (11b) in fluid communication with the cabin (2), and a second outlet (11c) in fluid communication with the heat exchanger (5), and a control unit (9) configured to determine if there is excess heat in the fluid entering the first valve (7) based on the measured temperature from the temperature sensor (8), control the first valve (7) so that the fluid is provided to the heater (6) when there is excess heat in the fluid and any of the energy storage system (3) and the cabin (2) needs to be heated, and control the second valve (11) so that the fluid from the heater (6) is distributed to the cabin (2) and/or to the heat exchanger (5) based on the need of heating of the cabin and the energy storage system.