Monoblock Heat Exchanger Segmentation for EV Battery Charging Cooling

Solution Overview

Problem

Conventional refrigerant/heat transfer liquid heat exchangers are inefficient in providing appropriate cooling power during normal charging modes of electric vehicle batteries, as they are designed for high cooling power requirements in rapid charging modes, leading to degraded performance in low-power scenarios.

Innovation Solution

A monoblock refrigerant/heat transfer liquid heat exchanger with two sealed heat exchange blocks and a partition plate, allowing for adjustable refrigerant and heat transfer liquid circulation paths to optimize cooling power based on charging modes, featuring U-shaped and I-shaped circulation paths and control valves for selective block usage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If the heat exchanger is configured to supply high cooling power for rapid charging mode, then the cooling power is sufficient for rapid charging, but the cooling performance is degraded in normal charging mode

Engineering Contradiction:

Improvecooling powerVSAvoidcooling performance

Core Design Contradiction:

PowerVSReliability

Solution Approach 1:

The heat exchanger is divided into two separate heat exchange blocks (first heat exchange block and second heat exchange block) that are sealed relative to each other and joined by a partition plate. This segmentation allows independent circulation paths for refrigerant and heat transfer liquid in each block, enabling selective activation based on cooling requirements. During rapid charging, both blocks are activated to provide high cooling power; during normal charging, only one block is activated to maintain optimal cooling performance.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If a single heat exchange block is used, then the device complexity is low, but the adaptability to different charging modes is insufficient

Engineering Contradiction:

Improveadaptability to charging modesVSAvoidheat exchanger structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The heat exchanger is divided into two separate heat exchange blocks (first heat exchange block and second heat exchange block) that are sealed relative to each other and joined by a partition plate. This segmentation allows independent circulation paths for refrigerant and heat transfer liquid in each block, enabling selective activation based on cooling requirements. During rapid charging, both blocks are activated to provide high cooling power; during normal charging, only one block is activated to maintain optimal cooling performance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system incorporates dynamic control through circulation path configuration that can be adjusted based on operating conditions. The partition plate with selective passage openings and control valves enable the system to dynamically switch between different operational states: both blocks active for rapid charging, or single block active for normal charging, thereby adapting to varying thermal demands.

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

The solution enables efficient and rapid supply of appropriate cooling power across various battery charging modes, improving cooling performance in both rapid and normal charging scenarios by optimizing heat exchange surfaces and fluid circulation.

Implementation Method 1

a refrigerant/heat transfer liquid heat exchanger that is arranged to allow a thermal transfer between the refrigerant and the heat transfer liquid

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Implementation Method 2

a first circulation path for a refrigerant and a first circulation path for a heat transfer liquid... a second circulation path for the refrigerant and a second circulation path for the heat transfer liquid

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS12172489B2Monoblock heat exchanger comprising at least two heat exchange blocks, each comprising a circulation path for a refrigerant and a circulation path for a heat transfer liquid

Publication Date: 2024.12.24 VALEO SYST THERMIQUES SAS

AI summary

The present invention relates to a refrigerant/heat transfer liquid heat exchanger (11), in which said refrigerant/heat transfer liquid heat exchanger is a monoblock refrigerant/heat transfer liquid heat exchanger (11). The refrigerant/heat transfer liquid heat exchanger (11) comprises at least two heat exchange blocks (41, 42) which are sealed with respect to one another, including a first heat exchange block (41) having a first circulation path for a refrigerant (21a) and a first circulation path for a heat transfer liquid (22a) and a second heat exchange block (42) having a second circulation path for a refrigerant (21b) and a second circulation path for a heat transfer liquid (22b). The heat exchange blocks (41, 42) are joined via a partition plate (40).