Fuel Cell Vehicle Thermal Loop Layout for Low-Drag Cooling
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Solution Overview
Problem
Current liquid cooling systems for fuel cell vehicles face challenges in thermal management, including inefficiencies in energy transfer, increased aerodynamic drag due to multiple radiators, and the need for specialized, costly coolants that may not offer optimal specific heat capacity or viscosity.
Innovation Solution
A hierarchical thermal management system with a 'backbone' ambient thermal loop and dedicated thermal loops for the fuel cell and electric drive units, utilizing a modular structure that allows for flexible operation modes and efficient heat exchange between components, thereby optimizing thermal conditioning and reducing coolant requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If multiple radiators are used for thermal management of different components, then thermal management effectiveness is improved, but aerodynamic drag increases
Solution Approach 1:
The patent combines multiple thermal management functions into a single integrated radiator unit. The radiator serves multiple components (fuel cell, electric motor, power electronics) simultaneously through a unified cooling circuit, eliminating the need for separate radiators for each component and thereby reducing aerodynamic drag while maintaining effective thermal management.
Solution Approach 2:
The single radiator is designed to perform multiple thermal management functions for different components of the fuel cell vehicle. It can cool the fuel cell stack, electric motor, and power electronics simultaneously or independently through a multi-circuit design, making the radiator a universal thermal management solution that reduces overall system complexity and drag.
2Reliability
If specialized dielectric coolants are used for fuel cell cooling, then electrical insulation is improved, but specific heat capacity and viscosity performance deteriorate
Solution Approach 1:
The cooling system is segmented into two separate circuits: a dielectric coolant circuit for fuel cell cooling where electrical insulation is critical, and a water-glycol coolant circuit for other components where thermal performance is prioritized. This segmentation allows each circuit to use the most appropriate coolant for its specific requirements without compromise.
Solution Approach 2:
A heat exchanger acts as an intermediary between the dielectric coolant circuit and the water-glycol coolant circuit. The dielectric coolant absorbs heat from the fuel cell and transfers it to the water-glycol coolant through the heat exchanger, allowing the system to maintain electrical insulation where needed while utilizing the superior thermal properties of water-glycol where electrical insulation is not required.
3Temperature
If complex liquid cooling systems are implemented for all components, then thermal management coverage is improved, but system complexity increases
Solution Approach 1:
The patent merges the thermal management systems for different components into a single integrated liquid cooling system. Multiple components (fuel cell, electric motor, power electronics) are connected to a unified cooling circuit with a single radiator and centralized pump system, reducing the number of independent cooling loops and simplifying system architecture while maintaining comprehensive thermal coverage.
Solution Approach 2:
The integrated cooling system is designed with multi-functionality to handle thermal management for various components through a single system architecture. The system can selectively direct coolant flow to different components based on their thermal requirements, providing comprehensive coverage without the complexity of multiple separate systems.
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 achieves faster thermal response, improved efficiency, and reduced costs by minimizing the size and complexity of cooling loops, allowing residual heat to be reused, and maintaining aerodynamic efficiency by reducing the number of exposed radiators.
Implementation Method 1
the fuel cell heat exchanger is a liquid to liquid heat exchanger arranged between the fuel cell thermal loop and the ambient thermal loop for exchanging heat between the fuel cell coolant and the ambient coolant; the drive heat exchanger is a liquid to liquid heat exchanger arranged between the drive thermal loop and the ambient thermal loop for exchanging heat between the drive coolant and the ambient coolant; and the ambient heat exchanger is a liquid to air heat exchanger arranged between the ambient thermal loop and an ambient air for exchanging heat between the ambient coolant and the ambient air
Data Source
Figure 1
Figure 2
AI summary
The present invention relates a fuel cell vehicle thermal system for thermal management of heat exchanged between an electrochemical fuel cell unit, an electric drive unit of a fuel cell vehicle and a thermal circuit (100) comprising a fuel cell thermal loop (20) and a drive thermal loop (30) separately. According to the invention, the thermal circuit (100) comprises an ambient thermal loop (10), a fuel cell heat exchanger (21) arranged between the fuel cell thermal loop (20) and the ambient thermal loop (10), a drive heat exchanger (31) arranged between the drive thermal loop (30) and the ambient thermal loop (10), and an ambient heat exchanger (11) arranged between the ambient thermal loop (10) and an ambient air.