Mobile Battery Fluid Loop for Fast-Charge Thermal Control
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Solution Overview
Problem
Charging systems for electric vehicles and aircraft often require significant capital investment and fixed infrastructure, which can limit operations and hinder the adoption of electric technology due to limitations in charging time and infrastructure flexibility.
Innovation Solution
A fluid management system for mobile charging systems that includes a thermal management loop with heat exchangers, pumps, and reversing valves, allowing for simultaneous cooling and heating of battery systems, and a purge and fill system to efficiently manage a working fluid, facilitating fast charging and reducing weight by purging media post-charge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fixed infrastructure charging systems are used, then charging reliability is improved, but adaptability and ease of operation deteriorate due to limited deployment flexibility and high infrastructure requirements
Solution Approach 1:
The charging system is divided into mobile charging units that can be independently deployed and moved to different locations, eliminating the need for fixed infrastructure while maintaining charging reliability through standardized interfaces and protocols
Solution Approach 2:
A fluid coupling mechanism serves as an intermediary between the mobile charging system and the battery system, enabling thermal management and charging operations without direct mechanical or electrical connections that would require fixed infrastructure
2Productivity
If fast charging is implemented, then productivity is improved, but thermal management complexity increases and battery life deteriorates due to heat generation
Solution Approach 1:
The system performs preliminary thermal conditioning of the battery by circulating fluid through thermal management channels before fast charging begins, ensuring the battery is at the optimal temperature to withstand high charging rates without degradation
Solution Approach 2:
The fluid circulation system operates continuously during fast charging, maintaining constant thermal management to remove heat as it is generated, thereby sustaining high charging speeds without compromising battery life through temperature control
3Temperature
If thermal management fluid is retained in the system, then thermal management effectiveness is improved, but weight increases which is critical for mobile and aircraft applications
Solution Approach 1:
The system dynamically adjusts fluid circulation based on thermal demands, activating pumps and circulation paths only when heating or cooling is required, thereby maintaining thermal management effectiveness while minimizing the weight penalty of carrying thermal management components and fluid
Solution Approach 2:
The thermal management system utilizes the battery's own thermal characteristics and the ambient environment to provide passive thermal regulation, reducing reliance on active fluid circulation and thereby minimizing the weight of thermal management components
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 enables efficient thermal management for both mobile and aircraft battery systems, minimizing battery life reduction during fast charging, enhancing the economic viability of electric aircraft, and reducing aircraft weight by efficiently managing thermal energy and fluid circulation.
Implementation Method 1
a thermal management loop including a first heat exchanger, a first pump, a first reversing valve, and an expansion valve
Implementation Method 2
a first pump, a second pump, and a third pump in the thermal management loop
Implementation Method 3
a first reversing valve, and a second reversing valve... the first reversing valve is in fluid communication with the first heat exchanger, the second heat exchanger, the third heat exchanger, and the second reversing valve
Implementation Method 4
a first reversing valve, and an expansion valve... the first reversing valve is in fluid communication with the expansion valve
Data Source
AI summary
A mobile charging system for electric vehicles may include a fluid management system. The fluid management system may be configured to be fluidly coupled to the electric vehicle. The fluid management system may be configured to provide heating or cooling to a vehicle battery system during charging of the vehicle battery system of the electric vehicle.