Integrated Thermal Management System for Fast-Charging Battery Cooling
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Solution Overview
Problem
The rapid increase in new energy vehicle users is hindered by the inability of existing charging stations to meet high-power fast charging demands, leading to heat generation that affects charging efficiency and convenience due to inadequate heat dissipation, which in turn impacts travel efficiency and vehicle usability.
Innovation Solution
A thermal management system for vehicles incorporating a compressor, external heat exchanger, first and second heat exchange plates, and a throttle valve group to dissipate heat from battery modules during charging, ensuring appropriate operating temperatures and extending battery life while optimizing interior space with integrated components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-power fast charging is implemented to reduce charging time, then charging efficiency is improved, but heat generation increases and cannot be dissipated timely
Solution Approach 1:
The patent merges the battery cooling function with the air conditioning system by integrating the evaporator to serve dual purposes: cooling the passenger compartment and cooling the battery module. The refrigerant circulation system is configured to provide cooling to both the evaporator and the battery module simultaneously, thereby resolving the heat dissipation problem during fast charging without requiring a separate cooling system.
Solution Approach 2:
The evaporator is designed with multi-functionality, serving both as part of the air conditioning system for passenger comfort and as a heat exchanger for battery cooling. This universal component performs multiple functions within the thermal management system, enabling efficient heat dissipation during fast charging while maintaining passenger comfort.
2Reliability
If separate cooling systems are added to dissipate battery heat, then heat dissipation capability is improved, but system complexity and space occupation increase
Solution Approach 1:
The patent combines the battery cooling system with the existing air conditioning system by integrating the evaporator and refrigerant circulation pathways. This merging approach enables the system to provide both passenger cooling and battery cooling functions through a unified thermal management architecture, reducing overall system complexity and component count.
Solution Approach 2:
The refrigerant circulation system is designed with universal functionality to serve multiple purposes: cooling the passenger compartment through the evaporator and cooling the battery module through the integrated cooling channels. This multi-functional design eliminates the need for separate cooling systems, thereby reducing device complexity and space occupation.
3Reliability
If traditional thermal management systems are used, then battery cooling is provided, but interior space is wasted and layout is irrational
Solution Approach 1:
The patent integrates the battery thermal management components with the vehicle's existing structural elements and air conditioning system. The evaporator and cooling channels are positioned to utilize available space efficiently, merging multiple functions into compact arrangements that reduce overall space occupation while maintaining effective battery cooling.
Solution Approach 2:
The cooling channels are designed to extend along the length direction of the battery module, utilizing the longitudinal space efficiently. This dimensional arrangement allows the cooling system to cover the entire battery module surface area without occupying excessive interior volume, thereby optimizing space utilization while ensuring reliable battery operation.
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 dissipates heat generated during fast charging, ensuring reliable battery operation, reducing maintenance frequency, improving charging efficiency, and facilitating a more rational vehicle layout by integrating thermal management components.
Implementation Method 1
the throttle valve group is disposed on the valve seat to throttle and reduce the pressure of the refrigerant flowing through the throttle valve group
Implementation Method 2
a first heat exchange plate and a second heat exchange plate, the first heat exchange plate and the second heat exchange plate are respectively configured for heat exchange with the battery module
Implementation Method 3
a compressor, the compressor includes an outlet and an inlet
Data Source
AI summary
A thermal management system for a vehicle includes a compressor, an external heat exchanger, a first heat exchange plate, a second heat exchange plate, and an integrated module. The integrated module comprises a valve seat and a throttle valve group. The external heat exchanger, an inlet of the compressor, two ends of a first flow channel of the first heat exchange plate and two ends of a second flow channel of the second heat exchange plate are connected to corresponding interfaces, respectively. The thermal management system has a battery cooling mode, and in the battery cooling mode, a throttled and depressurized refrigerant flowing out of the integrated module flows to at least one of the first flow channel and the second flow channel, and flows back to the integrated module to be discharged to the inlet.