Hydrocarbon Thermal Fluid for Electric Vehicle Heat Management

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Solution Overview

Problem

Current thermal management fluids for electric vehicles face challenges in effectively managing heat while ensuring safety, as aqueous solutions can cause electrical conductivity issues and risk of hydrogen formation, and existing non-aqueous fluids may not maximize heat removal efficiency.

Innovation Solution

A thermal management fluid comprising a base oil with a branch content of 15 mol.% to 30 mol.% and a naphthene content of 30 wt.% or less, which enhances thermal conductivity and minimizes power required for circulation, thereby improving heat removal efficiency and safety.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If aqueous thermal management fluids are used for indirect heat removal, then heat transfer capability is provided, but electrical conductivity issues and hydrogen formation risks occur

Engineering Contradiction:

ImprovesafetyVSAvoidelectrical conductivity and hydrogen formation risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the fundamental parameter of the thermal management fluid from aqueous-based to hydrocarbon-based, specifically using isoparaffinic fluids with controlled branch content (15-30 mol%). This parameter change eliminates water-related electrical conductivity and hydrogen formation risks while maintaining effective thermal management capabilities through optimized molecular structure

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs an inert hydrocarbon-based fluid environment替代aqueous solutions, creating a non-conductive and chemically stable atmosphere that eliminates electrical conductivity hazards and hydrogen formation risks associated with water-based fluids in electric vehicle thermal management systems

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

2Use of energy by moving object

If thermal management fluid circulation power is reduced, then energy efficiency improves, but heat removal effectiveness may decrease

Engineering Contradiction:

Improvepower consumption for fluid circulationVSAvoidheat removal effectiveness

Core Design Contradiction:

Use of energy by moving objectVSProductivity

Solution Approach 1:

The patent optimizes the molecular parameters of the hydrocarbon fluid, specifically controlling branch content at 15-30 mol% and naphthene content at ≤30 wt%, to achieve an optimal balance between viscosity (affecting circulation power) and thermal conductivity (affecting heat removal effectiveness). This parameter optimization allows reduced circulation power while maintaining heat removal performance

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses composite hydrocarbon formulations combining isoparaffinic base fluids with specific branch content and controlled naphthene content, creating a composite material that simultaneously achieves low viscosity for energy-efficient circulation and high thermal conductivity for effective heat removal from electric vehicle components

Inventive Principle:

Principle #40Composite materials

3Productivity

If direct thermal management is implemented, then heat removal effectiveness improves, but safety risks from electrical conductivity and hydrogen formation increase

Engineering Contradiction:

Improveheat removal effectivenessVSAvoidsafety

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent changes the fluid composition parameter from water-based to hydrocarbon-based with specific isoparaffinic structure (15-30 mol% branch content), enabling direct thermal management contact with electrical components without the safety risks of electrical conductivity and hydrogen formation that plague water-based direct cooling systems

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent converts the traditional disadvantage of hydrocarbon fluids (lower thermal conductivity compared to water) into a benefit by eliminating their electrical conductivity and chemical reactivity hazards, thereby enabling safe direct thermal management contact with electrical components that would be dangerous with aqueous fluids

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 proposed thermal management fluid effectively removes heat from electric systems while minimizing power consumption and reducing safety risks, ensuring efficient thermal management and compatibility with electric vehicle components.

Implementation Method 1

Direct thermal management may provide the effective thermal management of heat generated from hot surfaces

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

circulating a thermal management fluid into a contact with one or more components of the electric system to remove heat from the one or more components

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS11702577B2High thermal conductivity hydrocarbon thermal management fluids for electric vehicles

Publication Date: 2023.07.18 EXXONMOBIL TECHNOLOGY & ENGINEERING CO

AI summary

Disclosed are thermal management fluids for electric systems and methods of application. An example thermal management fluid may comprise: a base oil as a major component, wherein the base oil has both of the following enumerated properties: (i) a branch content of about 15 mol. % to about 30 mol. %; and (ii) a naphthene content of about 30 wt. % or less.