EV Thermal Management with Shared Heat Exchanger and Coolant Loops
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Solution Overview
Problem
Current electric vehicle thermal management systems are overly complex and inefficient, as they often rely on multiple independent heat management subsystems, which are not well-suited to meet the power train and HVAC system requirements effectively.
Innovation Solution
A simplified thermal management system is implemented, utilizing a single refrigeration system with three coolant loops: one for the power train, one for the battery, and one for the HVAC, with a shared heat exchanger to manage thermal loads efficiently, and air circulation through radiators to provide cabin heating and cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple independent thermal subsystems are used, then each subsystem can be optimized for its specific function, but the overall system complexity increases and efficiency decreases
Solution Approach 1:
The patent combines multiple independent thermal subsystems (power train cooling, battery cooling, and HVAC) into a single integrated thermal management system that shares common components including the heat exchanger, refrigeration system, and coolant loops. This merging reduces overall system complexity while maintaining the ability to independently manage thermal loads for each subsystem through controlled coolant flow distribution.
Solution Approach 2:
The integrated thermal management system employs universal components that serve multiple functions. The single heat exchanger handles thermal exchange for power train, battery, and HVAC subsystems. The refrigeration system provides cooling for all three subsystems. Coolant loops are configured to deliver cooling capacity to any or all subsystems as needed, making the system multi-functional and adaptable to various thermal management scenarios.
2Adaptability or versatility
If multiple independent thermal subsystems with separate components are used, then each subsystem can operate independently, but the number of components (pumps, valves, refrigerant systems) increases
Solution Approach 1:
The patent merges the refrigerant systems of multiple subsystems into a single shared refrigeration system. One compressor and condenser serve all thermal management needs. The coolant loops are interconnected to share the heat exchanger and refrigerant circulation infrastructure, significantly reducing the total number of components compared to independent subsystems while preserving the ability to independently control cooling to each subsystem through flow management.
3Device complexity
If a shared heat transfer medium is used across multiple circuits, then system complexity is reduced, but the interaction between circuits increases complexity
Solution Approach 1:
While using a shared heat transfer medium (refrigerant) across multiple circuits, the patent segments the coolant loops into distinct pathways for power train cooling, battery cooling, and HVAC. Each loop has its own circulation pump and flow control capabilities. This segmentation allows independent control of each circuit's coolant flow rate and timing, managing the complexity of circuit interactions while maintaining the benefits of a shared refrigeration system.
Solution Approach 2:
The system employs dynamic flow control where coolant circulation is adjusted in real-time based on thermal demands of different subsystems. Pumps and valves dynamically regulate coolant flow distribution to match varying thermal loads. This dynamic adaptability manages the complexity of shared circuit interactions by actively balancing thermal demands across power train, battery, and HVAC subsystems throughout operation.
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 approach reduces complexity and enhances efficiency by allowing for continuous and variable cooling control, meeting the thermal management needs of electric vehicles while minimizing components and improving user experience.
Implementation Method 1
cooling a heat exchanger with a refrigeration system
Implementation Method 2
circulating a first coolant within a first coolant loop coupled to the heat exchanger and the vehicle's energy storage system
Implementation Method 3
passing air through a radiator coupled to the second coolant loop
Data Source
AI summary
A method for managing thermal loads within an electric vehicle using an efficient thermal management system (100) that utilizes a single heat exchanger (133) is provided. A refrigeration subsystem (103) cools the heat exchanger (133). A first coolant loop (139) in thermal communication with the heat exchanger (133) is used to cool the energy storage system (137). A second coolant loop (151) corresponding to the HVAC subsystem (107) is also in thermal communication with the heat exchanger (133). Preferably a third coolant loop (109) corresponding to the drive motor cooling subsystem (101) is coupleable to the HVAC coolant loop (151), thus providing an efficient means of providing heat to the HVAC subsystem (107).