EV Thermal Management System with Configurable Valve Loops
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Solution Overview
Problem
Current thermal management systems for electric vehicles fail to efficiently control the temperature of battery packs, drive train components, and passenger cabins while maintaining overall vehicle operating efficiency, leading to suboptimal performance and increased energy consumption.
Innovation Solution
A thermally efficient and configurable thermal management system that includes a battery thermal control loop, a drive train control loop, a refrigerant-based thermal control loop, and a passenger cabin thermal control loop, with valve assemblies and heat exchangers that allow for parallel and serial operation modes to optimize temperature regulation across vehicle subsystems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple independent cooling loops are used to control battery and drive train temperatures, then temperature control reliability is improved, but system complexity and energy consumption increase
Solution Approach 1:
The patent combines multiple cooling loops (battery cooling loop and drive train cooling loop) into a unified thermal management system that can operate in different configurations. The system uses a single coolant circuit that can be arranged in parallel or series mode through valve control, reducing the number of independent pumps and heat exchangers while maintaining temperature control reliability for both battery and drive train components.
Solution Approach 2:
The patent implements dynamic switching between parallel and series cooling configurations using control valves. When parallel configuration is active, both battery and drive train receive independent cooling; when series configuration is active, cooling capacity is dynamically allocated based on thermal demands. This dynamic adaptability allows the system to optimize between reliability and complexity based on real-time operating conditions.
2Measurement precision
If separate thermal control loops are used for battery and drive train, then temperature regulation precision is improved, but energy consumption increases
Solution Approach 1:
The patent creates a universal thermal management system where a single coolant circuit serves multiple functions: it can cool the battery independently, cool the drive train independently, or provide coordinated cooling to both components. The system uses a common pump and coolant reservoir that can be distributed to different thermal zones through valve control, reducing energy consumption while maintaining precise temperature regulation through centralized control.
3Adaptability or versatility
If parallel cooling loop configuration is used, then temperature control adaptability is improved, but system complexity increases
Solution Approach 1:
The patent segments the thermal management system into modular components: a common coolant circuit, separate cooling outlets for battery and drive train, and independently controllable valve assemblies. Each segment can be controlled separately, allowing the system to adapt to different thermal demands while keeping the overall structure manageable. The segmentation enables flexible configuration switching without requiring complete system redesign.
4Use of energy by moving object
If series cooling loop configuration is used, then energy efficiency is improved, but temperature control versatility decreases
Solution Approach 1:
The patent implements feedback control mechanisms that monitor temperatures of both battery and drive train components, then dynamically adjust valve positions to switch between series and parallel configurations. When total thermal demand is low, the system operates in series mode for energy efficiency; when demand increases or temperature distribution requires independent control, the system switches to parallel mode. This feedback-driven adaptability resolves the trade-off between energy efficiency and versatility.
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 effectively regulates the temperature of battery packs, drive train components, and passenger cabins, enhancing vehicle performance, reducing energy consumption, and optimizing overall efficiency by allowing independent or coordinated operation of thermal control loops.
Implementation Method 1
a first heat exchanger thermally coupled to the battery pack
Implementation Method 2
a second heat exchanger thermally coupled to the drive train component
Implementation Method 3
the refrigerant valve in a second mode directs the refrigerant through the refrigerant-fluid heat exchanger which, in turn, heats the heat transfer fluid within the thermal control loop
Data Source
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AI summary
A multi-mode vehicle thermal management system is provided that allows efficient thermal communication between a refrigerant-based thermal control loop (501), which may be operated in either a heating mode or a cooling mode, and multiple non-refrigerant-based thermal control loops like battery (509) control loop (505), passenger cabin control loop 503) and drive train control loop (507) . As a result of this approach, the system is able to efficiently regulate the temperature within the various vehicle thermal control loops, for example utilizing the heat generated within one subsystem (501) to heat another subsystem (503,505). A valve assembly (563) connects or separates battery loop (505) and drive train loop (507).