Integrated Chiller Valve for Battery Thermal Management

Solution Overview

Problem

Existing vehicle battery cooling systems require extensive and costly installations with many lines and T-pieces, leading to high assembly expenses and complexity, especially when incorporating chillers for efficient heat transfer in varying ambient temperatures.

Innovation Solution

A first valve device is integrated within the chiller or attached directly to it, reducing the number of external interfaces and lines by allowing coolant flow division between the chiller and coolant cooler, thereby simplifying assembly and reducing parts variety and installation space requirements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a chiller is incorporated in the refrigerant circuit for efficient battery cooling, then cooling efficiency is improved, but device complexity and assembly cost increase due to many lines and T-pieces

Engineering Contradiction:

Improvecooling efficiencyVSAvoidnumber of lines and T-pieces

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the chiller and coolant cooler into a single integrated heat exchanger unit with a common housing. The refrigerant circuit and coolant circuit are merged within this single component, eliminating the need for separate chillers, coolers, and multiple connecting lines. This integration maintains cooling efficiency while reducing device complexity and assembly cost.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated heat exchanger performs multiple functions simultaneously: it acts as both a chiller (for efficient cooling when ambient temperature is low) and a coolant cooler (for passive cooling when ambient temperature is high). The single device adapts to different operating conditions through the valve device that directs coolant flow to appropriate heat exchange paths, eliminating the need for separate dedicated components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If a chiller is incorporated in the refrigerant circuit for efficient battery cooling, then cooling efficiency is improved, but manufacturing cost increases due to substantial assembly effort

Engineering Contradiction:

Improvecooling efficiencyVSAvoidassembly expenditure

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines the chiller and coolant cooler into a single integrated heat exchanger unit with a common housing. The refrigerant circuit and coolant circuit are merged within this single component, eliminating the need for separate chillers, coolers, and multiple connecting lines. This integration maintains cooling efficiency while reducing device complexity and assembly cost.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If multiple cooling paths (chiller only, coolant cooler only, or combination) are provided for different ambient temperatures, then adaptability is improved, but device complexity increases due to additional lines and change-over valves

Engineering Contradiction:

Improvetemperature control flexibilityVSAvoidparts variety

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The integrated heat exchanger performs multiple functions simultaneously: it acts as both a chiller (for efficient cooling when ambient temperature is low) and a coolant cooler (for passive cooling when ambient temperature is high). The single device adapts to different operating conditions through the valve device that directs coolant flow to appropriate heat exchange paths, eliminating the need for separate dedicated components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system dynamically adapts to different ambient temperature conditions through the valve device that can redirect coolant flow between different heat exchange paths within the integrated unit. This dynamic flow control allows the single device to provide optimal cooling performance across varying environmental conditions without requiring multiple fixed configurations.

Inventive Principle:

Principle #15Dynamics

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 configuration enables efficient temperature control of vehicle batteries with reduced assembly and manufacturing costs, while allowing for flexible temperature adjustments and efficient cooling or heating, particularly in electric or hybrid vehicles.

Implementation Method 1

a chiller (9) which is additionally incorporated in a refrigerant circuit (10), in which in addition a compressor (11), a condenser (12) and an evaporator (13) are arranged

Methodology Applied

Scientific EffectHeat transfer: Heat Exchanger

Implementation Method 2

a coolant cooler (7)

Methodology Applied

Scientific EffectHeat dissipation: Heat Sink

Implementation Method 3

a first valve device (14) for dividing a coolant flow into a first coolant flow and a second coolant flow

Methodology Applied

Scientific EffectFluid flow control: Valve

Data Source

PatentUS11637336B2Device for cooling a battery

Publication Date: 2023.04.25 MAHLE INT GMBH

AI summary

A device for temperature-controlling a vehicle battery in an electric or hybrid vehicle may include a coolant circuit, a refrigerant circuit, and a first valve device. The vehicle battery, a coolant cooler, a coolant pump, and a chiller may be arranged in the coolant circuit. The chiller, a compressor, a condenser, and an evaporator may be arranged in the refrigerant circuit. The first valve device may be arranged indirectly on the chiller. A coolant flow may be dividable between the chiller and the coolant cooler via the first valve device.