Five-Port Valve Module for EV Fast-Charging Battery Cooling
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Solution Overview
Problem
Fast charging of electric vehicle batteries generates excessive heat, leading to increased internal resistance, accelerated aging, and potential thermal runaway, posing safety risks and reducing battery life.
Innovation Solution
A valve system with an expansion valve and modular connections to heat exchangers, allowing for various thermal management modes with improved cooling performance, including a five-way valve and multiple junction points for flexible pipeline configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If fast charging power is increased to reduce charging time, then charging speed is improved, but battery temperature rise and heat generation increase
Solution Approach 1:
The thermal management system divides the cooling circuit into multiple independent flow paths with separate control valves (first cooling circuit valve, second cooling circuit valve, third cooling circuit valve). Each flow path can be independently controlled to direct coolant flow to different heat exchangers based on thermal management requirements, enabling precise temperature control during fast charging
Solution Approach 2:
The system uses dynamically controllable valves to adjust coolant flow distribution in real-time based on battery temperature conditions. The control unit monitors battery temperature and automatically adjusts valve positions to optimize cooling efficiency, transitioning between different thermal management modes as charging progresses
2Reliability
If complex valve systems are added to improve thermal management capability, then cooling performance is improved, but system complexity increases
Solution Approach 1:
The thermal management system employs a multi-functional valve module that can perform multiple functions: regulating coolant flow to different heat exchangers, switching between series and parallel circuit configurations, and adapting to various charging modes. This single integrated valve system replaces what would otherwise require multiple separate control mechanisms, reducing overall system complexity while maintaining comprehensive thermal management capability
Solution Approach 2:
The valve system is designed with a nested modular structure where the valve module contains integrated control elements within a compact housing. The first, second, and third cooling circuit valves are arranged in a nested configuration sharing common mounting structures and control mechanisms, reducing space requirements and simplifying installation while maintaining independent control functionality
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
Enables efficient thermal management during fast charging by effectively managing heat generation, reducing temperature rise, and enhancing battery life through simple and adaptable thermal management systems.
Implementation Method 1
an expansion valve (101), wherein a first flow path (L1) is provided between the first port (V1) and the second port (V2); the expansion valve (101) is arranged on the first flow path (L1)
Implementation Method 2
the expansion valve (101) is arranged on the first flow path (L1)
Implementation Method 3
the valve module (102) is respectively connected to a third port (V3), a fourth port (V4) and a fifth port (V5), and is further connected to the first port (V1)
Data Source
Figure 1
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Figure 3
AI summary
A valve system (100) and a thermal management system. The valve system (100) comprises an expansion valve (101), a valve module (102), a first port (V1), a second port (V2), a third port (V3), a fourth port (V4), and a fifth port (V5). A first flow path (L1) is provided between the first port (V1) and the second port (V2). The expansion valve (101) is arranged on the first flow path (L1). The valve module (102) is communicated with the third port (V3), the fourth port (V4) and the fifth port (V5), respectively, and is also communicated with the first port (V1). The valve system has a simple structure and connection mode, so that the thermal management system comprising the valve system can achieve efficient thermal management in a quick charge mode of a vehicle, and thus has improved refrigeration performance.