Integrated Thermal Management for Cabin and Battery Pack
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Solution Overview
Problem
Current thermal management systems in hybrid-electric, plug-in hybrid electric, and battery electric vehicles are inefficient in optimizing cabin and battery pack temperature control, often requiring separate heating and cooling mechanisms that do not effectively utilize heat generated by power electronics to maintain battery pack temperature and provide occupant comfort.
Innovation Solution
A thermal system with controllable valves and coolant loops that allow for various modes of operation, including cabin heating, battery pack heating, and recirculation, to efficiently distribute heat generated by power electronics and coolant heaters to both the cabin and battery pack, optimizing energy use and maintaining battery pack temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate heating and cooling mechanisms are used for cabin and battery pack, then temperature control reliability is improved, but energy consumption increases and system complexity increases
Solution Approach 1:
The patent merges the cabin thermal management system and battery pack thermal management system into a single integrated system. The coolant circulation system serves both the cabin (via heater core and AC evaporator) and the battery pack (via battery coolant passages), allowing heat generated by the engine or power electronics to be utilized for both cabin heating and battery temperature maintenance, thereby reducing overall energy consumption while maintaining reliable temperature control for both subsystems
Solution Approach 2:
The thermal management system is designed with multi-functionality where the same coolant circulation system performs multiple functions: cooling the cabin via AC evaporator, heating the cabin via heater core, and temperature control of the battery pack. The controllable valves enable the system to dynamically allocate coolant flow to different components based on thermal demands, making the system universal and adaptable to various operating conditions without requiring separate dedicated systems
2Loss of energy
If heat from power electronics is utilized for cabin heating, then energy efficiency is improved, but system complexity increases
Solution Approach 1:
The patent combines the power electronics cooling function with the cabin heating function by routing coolant from the power electronics (which generates heat during operation) through the heater core to heat the cabin. This merging allows the waste heat from power electronics to be recovered and utilized, improving overall energy efficiency. The controllable valves enable this heat recovery path to be activated when cabin heating is needed, integrating multiple functions into a unified thermal management architecture
3Adaptability or versatility
If multiple controllable valves are used to manage coolant flow paths, then thermal management versatility is improved, but device complexity increases
Solution Approach 1:
The patent employs controllable valves that can dynamically adjust coolant flow paths based on real-time thermal demands of the cabin and battery pack. The valves enable the system to switch between different operating modes (e.g., cabin cooling only, battery cooling only, combined cabin and battery cooling, heat recovery modes) by dynamically routing coolant through different components. This dynamic adaptability allows a single system to handle multiple thermal management scenarios, achieving high versatility while the control logic manages the complexity of coordinating multiple valves
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 effectively utilizes heat generated by power electronics and coolant heaters to efficiently heat and cool the cabin and battery pack, reducing energy consumption and maintaining battery pack temperature, thereby enhancing thermal management and occupant comfort.
Implementation Method 1
circulate liquid coolant through power electronics in the power electronics coolant loop and through a heater core in the cabin cooling loop to utilize heat generated by the power electronics to heat the cabin
Implementation Method 2
circulate liquid coolant through an energized coolant heater in the cabin coolant loop and the heater core to utilize heat generated by the coolant heater to heat the cabin
Implementation Method 3
heat generated by the power electronics to heat the cabin
Data Source
AI summary
A motor vehicle has an electric traction motor and a battery pack that provides power to the motor. The battery pack includes a plurality of battery cells. A thermal system includes a battery pack coolant loop, a cabin coolant loop, a power electronics coolant loop and a plurality of controllable valves controlled by a controller to select thermal modes by controlling flow paths of coolant in one or more of the coolant loops.