Five-Way Coolant Valve Layout for Battery Loop Pressure Relief
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Solution Overview
Problem
In vehicle thermal management systems, the absence of a reservoir in one of the coolant loops leads to excessive pressure increase due to heat medium expansion, potentially causing component deterioration when the loops are connected in parallel.
Innovation Solution
A thermal management system with a switching valve that connects two circuits, one with a reservoir and one without, allowing for modes that absorb pressure increases by redirecting heat medium flow through the reservoir, preventing component damage and allowing independent temperature control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the battery system coolant loop is configured without a reservoir to simplify the circuit structure, then the device complexity is reduced, but the internal pressure of the circuit may be excessively increased due to heat medium expansion
Solution Approach 1:
The switching valve acts as an intermediary component that enables controlled interaction between the battery system coolant loop and the drive train coolant loop. By switching between series and parallel connections, it allows the drive train coolant loop (with reservoir) to absorb pressure increases from the battery system coolant loop (without reservoir), preventing excessive pressure buildup while maintaining circuit simplicity
Solution Approach 2:
The patent merges the battery system coolant loop and drive train coolant loop into a unified thermal management system where the two circuits can operate in different connection modes. The drive train coolant loop serves as a pressure absorption reservoir for the battery system coolant loop through the switching valve, allowing pressure equalization without adding a reservoir to the battery system coolant loop
2Adaptability or versatility
If the first circuit and second circuit are connected together in parallel to enable independent temperature control, then the adaptability is improved, but the pressure increase of the heat medium in the second circuit is not absorbed
Solution Approach 1:
The switching valve provides dynamic reconfiguration of the circuit topology, allowing the system to switch between parallel connection (for independent temperature control) and series connection (for pressure absorption). This dynamic switching enables the system to maintain adaptability while preventing excessive pressure buildup by changing the connection mode when needed
3Reliability
If the switching valve redirects heat medium flow through the reservoir to absorb pressure increases, then the reliability is improved, but the device complexity increases
Solution Approach 1:
The drive train coolant loop with the reservoir serves multiple functions: it cools the drive train components (inverter, power converter, motor) and simultaneously acts as a pressure absorption reservoir for the battery system coolant loop. The switching valve enables this multi-functionality by redirecting heat medium flow between the two circuits, protecting components from excessive pressure without requiring additional dedicated pressure absorption components
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
Prevents component deterioration by absorbing pressure increases and allows for independent temperature control of the circuits, ensuring reliable operation of the vehicle's thermal management system.
Implementation Method 1
expansion (pressure increase) of the heat medium due to a temperature change of the heat medium is not absorbed in the circuit
Data Source
AI summary
A thermal management circuit has a LT circuit including a reservoir tank and a battery circuit not including the reservoir tank. The thermal management system includes an ECU that controls a five-way valve to switch a plurality of modes with regard to a flow path for a heat medium in the thermal management circuit. The plurality of modes include a first mode (first circuit mode) and a second mode (third circuit mode). The first mode is a mode in which the LT circuit and the battery circuit are connected together in series. The second mode is a mode in which the LT circuit and the battery circuit are connected together in parallel and part of the heat medium flowing in the battery circuit flows to the LT circuit via the five-way valve.