Multi-port Valve Thermal Management for EV Energy Storage
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Solution Overview
Problem
Current thermal management systems for electric and hybrid vehicles face challenges in efficiently managing heat transfer among the vehicle cabin, energy storage systems, and power electronics, particularly during extreme operating conditions such as DC fast charging, off-road operation, and towing, which can lead to cell-to-cell temperature variations and reduced battery performance.
Innovation Solution
A thermal management system utilizing a multi-port valve assembly to selectively interconnect the cabin, energy storage system, and power electronics thermal management loops, allowing for reversible flow and waste heat recovery, thereby enhancing thermal uniformity and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If separate thermal management systems are used for cabin, ESS, and PE, then each system can be optimized independently, but the overall energy efficiency is reduced and system complexity increases
Solution Approach 1:
The patent combines three separate thermal management systems (cabin, ESS, and PE) into a single integrated thermal management system. The multi-port valve assembly enables these previously separate loops to share common components and coolant flow paths, allowing heat transfer among all three systems to occur within a unified architecture, thereby improving overall energy efficiency while managing complexity through integrated control.
Solution Approach 2:
The integrated thermal management system enables components and coolant loops to serve multiple functions simultaneously. For example, the same coolant loop can provide cooling to both ESS and PE, or transfer heat from PE to cabin heating. The multi-port valve assembly enables a single system architecture to perform multiple thermal management functions across different operating conditions, reducing the need for separate dedicated systems.
2Adaptability or versatility
If a simple thermal management system is used, then the system complexity is reduced, but the ability to handle varied operating conditions (DC fast charging, off-road operation, towing) is insufficient
Solution Approach 1:
The thermal management system incorporates a dynamic multi-port valve assembly that can reconfigure coolant flow paths in real-time based on operating conditions. The valve assembly allows the system to adapt between different thermal management modes (e.g., cooling ESS during fast charging, heating cabin during cold operation, cooling PE during towing) by dynamically redirecting coolant flow, thereby achieving high adaptability without requiring completely separate systems for each operating condition.
3Use of energy by moving object
If heat transfer among cabin, ESS, and PE is not managed holistically, then system control is simpler, but energy efficiency is reduced and load distribution is inappropriate
Solution Approach 1:
The integrated thermal management system incorporates control mechanisms that monitor thermal conditions across all three loops (cabin, ESS, PE) and dynamically adjust the multi-port valve assembly to optimize heat transfer. This feedback control enables the system to holistically manage energy distribution, transferring heat from hot components to cold components or to the cabin as needed, thereby improving energy efficiency while maintaining manageable control through sensor-based monitoring and automated valve control.
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 approach improves battery performance, fast charging rates, and real-world driving range by optimizing energy transfer and reducing temperature variations within the battery pack.
Implementation Method 1
a multi-port valve assembly coupled to the cabin thermal management loop, the energy storage system thermal management loop, and the power electronics thermal management loop and adapted to, responsive to an operating state of the vehicle, selectively isolate and couple the cabin thermal management loop, the energy storage system thermal management loop, and the power electronics thermal management loop from and to one another
Implementation Method 2
manage energy transfer in a more efficient and holistic manner among the cabin, ESS, and PE of a vehicle... enables reversible flow across the ESS to enhance cell-to-cell thermal uniformity, the recovery of waste heat from the ESS and/or PE
Data Source
AI summary
A thermal management system and method for a vehicle, including: a heat-cold source thermal management circuit; an energy storage system thermal management circuit; a power electronics thermal management circuit; and a multi-port valve assembly coupled to the heat-cold source thermal management circuit, the energy storage system thermal management circuit, and the power electronics thermal management circuit and adapted to, responsive to an operating state of the vehicle, selectively couple and isolate the heat-cold source thermal management circuit, the energy storage system thermal management circuit, and the power electronics thermal management circuit to and from one another.