Parallel Coolant Circuit for Dual-Temperature EV Thermal Management
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Solution Overview
Problem
Electric vehicles require a cooling system that can maintain two distinct temperature levels for batteries and electric components, which is challenging due to high constraints on costs, weight, packaging, and efficiency, as existing solutions often necessitate duplicating coolant circuit loops and multiple components.
Innovation Solution
A thermoregulation system with a divided coolant circuit featuring a main branch for battery cooling and a secondary branch for electric machine and power electronics, using a single pump and heat exchangers to achieve parallel coolant circulation, reducing component count and optimizing temperature management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If two separate coolant circuit loops are used to obtain two temperature levels, then temperature management capability is improved, but device complexity and component count increase
Solution Approach 1:
The patent merges two separate coolant circuit loops into a single integrated circuit with a divided structure. The first branch cools batteries to lower temperatures (20-35°C) while the second branch cools electric machines and power electronics to higher temperatures (50-60°C). This single circuit eliminates the need for multiple pumps, radiators, and expansion tanks, reducing component count while maintaining dual temperature level capability.
Solution Approach 2:
The coolant circuit is segmented into two distinct branches within a single integrated system. The first branch is dedicated to battery cooling with its own heat exchanger and flow control, while the second branch handles electric machine and power electronics cooling. This segmentation allows independent temperature management for each component type without requiring completely separate circuits.
2Temperature
If two separate coolant circuit loops are used, then temperature management is improved, but system weight increases
Solution Approach 1:
By combining multiple cooling functions into a single integrated coolant circuit, the patent eliminates redundant components such as duplicate pumps, radiators, and expansion tanks. This merging strategy significantly reduces the overall weight of the thermal management system while maintaining the ability to provide separate temperature control for batteries and electric machines.
3Temperature
If two separate coolant circuit loops are used, then temperature management is improved, but packaging volume increases
Solution Approach 1:
The integrated coolant circuit design merges multiple cooling loops into a single compact system. By sharing common components such as the pump, radiators, and expansion tanks between the two temperature levels, the patent reduces the total packaging volume required for the thermal management system while maintaining separate cooling pathways for batteries and electric machines.
4Temperature
If two separate coolant circuit loops are used, then temperature management is improved, but system cost increases
Solution Approach 1:
The patent reduces system cost by merging two separate coolant circuit loops into a single integrated circuit. This approach eliminates the need for duplicate components such as pumps, radiators, and expansion tanks, thereby reducing material costs, manufacturing complexity, and assembly requirements while maintaining the capability to manage two distinct temperature levels for different vehicle 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
This approach allows for effective cooling of batteries to lower temperatures while maintaining higher temperatures for electric machines and power electronics with fewer components, reducing costs, weight, and complexity, while also enabling efficient heating for the cabin.
Implementation Method 1
coolant heat exchangers, connected to the coolant circuit so that the coolant may circulate through them and comprising: a main exchanger, configured for exchanging heat between the coolant and air coming from the outside of the vehicle
Implementation Method 2
at least one battery exchanger, configured for exchanging heat between the coolant and said at least one battery
Implementation Method 3
a pump for circulating the coolant
Data Source
AI summary
This thermoregulation system (1) for an electrically driven vehicle (V), the vehicle comprising at least one electric machine (E), at least one battery (30), and at least one power electronics component (37), comprises a coolant circuit (5), a pump (7), coolant heat exchangers, connected to the coolant circuit (5) so that the coolant may circulate through them and comprising a main exchanger (9), configured for exchanging heat between the coolant and air coming from the outside of the vehicle (V), at least one battery exchanger (11), configured for exchanging heat between the coolant and said at least one battery (30), and at least one secondary exchanger (13, 36), configured for exchanging heat between the coolant and said at least one electric machine (E) and/or said at least one power electronics component (37). The coolant circuit (5) is divided in a first branch (B1), which comprises the main exchanger (9) and the at least one battery exchanger (11), a second branch (B2) which comprises the at least one secondary exchanger (13, 36), the coolant being circulated in parallel in the first and second branches (B1, B2), and a pump branch (PB) to which the pump (7) is connected, the pump branch (PB) being connected to the first and second branches (B1, B2) by an upstream and a downstream connection points (P1, P2) so that the coolant circulating in the pump branch (PB) is formed by a mix of the coolant circulating in the first branch (B1) and of the coolant circulating in the second branch (B2), and is directed towards the first and second branches (B1, B2) downstream the pump (7).