External Cooling Device for Electric Vehicle Battery Thermal Management
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Solution Overview
Problem
Existing electric vehicle charging systems face challenges in effectively cooling in-vehicle batteries during quick charging, especially when the internal cooling device's capacity is insufficient or when heat-pump heating is in progress, leading to potential battery deterioration and inefficiencies.
Innovation Solution
A charging system installed outside the electric vehicle, comprising a charger, an external cooling device, and an off-vehicle controller, which includes a compressor, heat exchanger, and bypass channel to cool the in-vehicle battery using external refrigerant, allowing for efficient cooling even when internal cooling is insufficient, and enabling heat transfer to warm another vehicle or facility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If quick charging is performed with high current, then charging time is reduced, but heat generation increases causing battery temperature rise
Solution Approach 1:
The cooling function is segmented into internal cooling device (within vehicle) and external cooling device (at charging station). The internal cooling device handles normal cooling needs, while the external cooling device provides additional cooling capacity during quick charging when heat generation is excessive. This segmentation allows each cooling system to be optimized for its specific operating conditions.
Solution Approach 2:
A refrigerant circulation system acts as an intermediary between the battery and the external environment. The refrigerant absorbs heat from the battery through the heat exchanger, transports it outside the vehicle, and dissipates it to the atmosphere, providing an efficient heat transfer pathway that prevents direct thermal buildup at the battery.
2Ease of operation
If air-conditioning compressor is used for cooling, then cooling function is provided, but capacity is insufficient for quick charging and cannot be used when heat-pump heating is in progress
Solution Approach 1:
The external cooling device at the charging station provides a universal cooling solution that can serve multiple vehicles simultaneously and operates independently of the vehicle's internal cooling system. It can provide cooling during quick charging, during heat-pump heating operations, and can handle cooling demands that exceed the internal cooling device's capacity.
Solution Approach 2:
The cooling problem is solved by moving the cooling capacity from the vehicle dimension (internal cooling device with limited power) to the charging infrastructure dimension (external cooling device with sufficient power). This dimensional shift allows access to much larger cooling capacity without compromising the vehicle's internal system design.
3Reliability
If internal cooling device is used, then cooling is provided, but capacity is insufficient when quick charging generates excessive heat
Solution Approach 1:
The internal cooling device and external cooling device are merged into a coordinated cooling system. The off-vehicle controller communicates with the in-vehicle controller to determine when quick charging is occurring and when additional cooling is needed, then activates the external cooling device to supplement the internal cooling device, ensuring reliable cooling without requiring either system to be oversized.
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 configuration ensures effective cooling of in-vehicle batteries during quick charging, reduces electricity consumption, and allows for efficient charging of multiple vehicles while preventing battery deterioration, and can also warm up another vehicle's battery or provide heat to external facilities.
Implementation Method 1
a heat exchanger configured to exchange heat between the cooled external refrigerant and an internal refrigerant that flows inside the electric vehicle so as to cool the in-vehicle battery or between the cooled external refrigerant and outside air that is sent to the electric vehicle so as to cool the in-vehicle battery
Implementation Method 2
The cooling mechanism includes at least a compressor
Data Source
AI summary
A charging system is installed outside an electric vehicle to charge an in-vehicle battery mounted in the electric vehicle. The charging system includes a charger that supplies electricity to the in-vehicle battery, an external cooling device that cools the in-vehicle battery, and an off-vehicle controller that controls driving of the charger and the external cooling device. The external cooling device has an external channel which is provided inside the charging system and through which an external refrigerant flows, cooling mechanisms that include at least a compressor and cool the external refrigerant, and a heat exchanger that exchanges heat between the cooled external refrigerant and an internal refrigerant that flows inside the electric vehicle to cool the in-vehicle battery or outside air that is sent to the electric vehicle to cool the in-vehicle battery.