Hydronic Battery Thermal Loop for EV Cabin Temperature Sharing
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Solution Overview
Problem
Electric vehicle batteries require optimal temperature management to achieve maximum performance, efficiency, and longevity, but existing systems lack an efficient method to provide ancillary heating and cooling for both the battery and the vehicle's occupant zone.
Innovation Solution
A battery heating and cooling system that is fluidly connected to an occupant zone hydronic system, allowing coolant to be directed between the two systems to regulate the temperature of both the battery and the occupant zone based on target temperature ranges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate heating and cooling systems are used for the battery and occupant zone, then each system can be optimized independently, but the overall device complexity and energy consumption increase
Solution Approach 1:
The patent combines the battery thermal management system and occupant zone climate control system into a single integrated system. The battery cooling system includes a refrigeration circuit that provides cooling to both the battery pack and the occupant zone through shared refrigerant flow paths and heat exchangers. This merging eliminates the need for separate independent systems while maintaining reliable temperature control for both functions.
Solution Approach 2:
The refrigeration circuit is designed to perform multiple functions: cooling the battery pack, cooling the occupant zone, and potentially heating the occupant zone through heat pump operation. The system uses a single refrigeration circuit with configurable flow paths that can serve different thermal management needs, making the system universal and multi-functional rather than requiring separate dedicated systems.
2Ease of operation
If a dedicated climate control system is used for the occupant zone, then occupant comfort is ensured, but energy consumption increases and battery charging efficiency decreases
Solution Approach 1:
The system recovers thermal energy that would otherwise be wasted. When the battery is being cooled, the refrigeration circuit captures the thermal energy from the battery and redirects it to heat the occupant zone when needed, or stores it for later use. This heat recovery mechanism discards none of the thermal energy but rather repurposes it, reducing the energy required for separate heating operations.
Solution Approach 2:
The battery thermal management system serves dual purposes: managing battery temperature and providing climate control for the occupant zone. The system essentially provides self-service by using the thermal energy from battery operation to maintain occupant comfort, rather than requiring an entirely separate energy-consuming climate control system.
3Reliability
If the battery is cooled aggressively to maintain optimal temperature, then battery performance and longevity are improved, but the occupant zone may become uncomfortably cold
Solution Approach 1:
The system provides different thermal conditions to different zones as needed. The battery pack receives aggressive cooling when required for optimal performance and longevity, while the occupant zone receives conditioned air at comfortable temperatures. The refrigeration circuit is designed with separate control paths that allow localized temperature control - the battery can be cooled to 25°C while the occupant zone is maintained at 70°F, with each zone independently controlled according to its specific requirements.
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 integrated system effectively manages the temperature of both the battery and the occupant zone, enhancing the battery's performance, efficiency, and lifespan while providing comfort to vehicle occupants.
Implementation Method 1
operate the refrigeration circuit to heat or cool coolant circulating though the battery heating/cooling loop to heat or cool the battery toward a target battery temperature
Implementation Method 2
coolant circulating though the battery heating/cooling loop to heat or cool the battery
Implementation Method 3
direct the coolant circulating though the battery heating/cooling loop to the hydronic system heating/cooling loop to heat or cool the occupant zone
Data Source
AI summary
A battery heating and cooling system may be used to provide ancillary heating and cooling to an occupant zone of a vehicle. The battery heating and cooling system may include a battery heating/cooling loop and a hydronic system heating/cooling loop. Upon receiving an indication to heat/cool the occupant zone, a battery management system may cause the battery heating and cooling system to direct coolant to the hydronic system heating/cooling loop to heat/cool the occupant zone toward a target occupant zone temperature. In some examples, the battery heating and cooling system directs coolant to the hydronic system heating/cooling loop during battery preconditioning or while heating/cooling the battery during operation of the vehicle. The target occupant zone temperature may correspond to a target battery temperature.