EV Thermal Loop Architecture for Off-Plug Battery and Cabin Heating
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Solution Overview
Problem
Managing heat transfer between components in electrified vehicles without adding significant heat exchangers and valve systems is challenging.
Innovation Solution
A thermal management system utilizing a glycol-based system with a first and second valve to enable battery heating and cabin heating independently, even when the vehicle is off-charge, and incorporating a refrigerant system with a chiller and heat exchanger for additional heating and cooling capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple heat exchangers and valve systems are added to manage heat transfer between components, then heat transfer management capability is improved, but device complexity increases
Solution Approach 1:
The glycol system is designed to serve multiple functions: it provides battery heating, cabin heating, and works with the refrigerant system for cooling. The same glycol loops and valves are used across different operational modes (battery heating off-plug, cabin heating, refrigerant cooling), eliminating the need for separate dedicated systems for each function.
Solution Approach 2:
The patent combines the battery thermal management system and cabin climate control system into a unified glycol-based thermal management architecture. The glycol loops serve both battery heating and cabin heating needs, and integrate with the refrigerant system for cooling, reducing the overall number of components.
2Device complexity
If a glycol system with limited valves is used for battery heating off-plug and independent cabin heating, then device complexity is reduced, but operational flexibility may be limited
Solution Approach 1:
The two valves in the glycol system are dynamically controlled to reconfigure flow paths based on operational requirements. The valves can create different circulation patterns to enable battery heating off-plug, independent cabin heating, or integration with the refrigerant system for cooling, providing operational flexibility despite having fewer valves.
Solution Approach 2:
The glycol system is designed to autonomously provide heating services through strategic valve control. The system can independently manage battery heating and cabin heating without requiring additional active components, using the existing glycol loops and two valves to self-regulate thermal management across different modes.
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
Effectively manages heat transfer in electrified vehicles by allowing battery heating and cabin heating without additional heat exchangers or valves, enhancing battery efficiency and comfort.
Implementation Method 1
manages heat transfer between different groups of components in the electrified vehicle
Implementation Method 2
A thermal management system for an electrified vehicle that provides battery heating off plug
Implementation Method 3
the refrigerant heat exchanger fluidly communicates with ambient atmosphere for cooling/heating
Implementation Method 4
the chiller fluidly communicates with the glycol system for cooling/heating
Implementation Method 5
the heater loop includes a PTC heater and a heater core
Data Source
AI summary
An exemplary thermal management system includes, among other things, a heater loop, a battery loop, a radiator loop, and a power electronics loop operating within a glycol system. A first valve is in fluid communication with one or more of the heater loop, the battery loop, the radiator loop, and the power electronics loop. A second valve in fluid communication with one or more of the heater loop, the battery loop, the radiator loop, and the power electronics loop. The second valve is fluidly connected to the first valve to provide at least one operational condition where there is battery heating within the battery loop while a vehicle is off charge, and while also being able to independently heat a cabin.