Passive Heat Exchanger for Vehicle Charging Thermal Loads
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Solution Overview
Problem
Conventional thermal management systems for vehicles, particularly during charging operations, often require active components like fans and coolant pumps, which consume power, require maintenance, and can disrupt other critical systems, such as computing operations in autonomous vehicles.
Innovation Solution
The implementation of a passive thermal management system using an onboard passive heat exchanger that includes a cold plate reservoir with a refrigerant and a condenser, which dissipates heat without active components, thereby not adding a thermal load to the existing coolant loop, and can be positioned in the airflow path of the radiator fan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If active thermal management components (fans, coolant pumps) are used during vehicle charging, then heat dissipation effectiveness is improved, but power consumption increases and system reliability decreases
Solution Approach 1:
The patent extracts the thermal management function for charging operations from the main active thermal management system. A separate passive heat exchanger is implemented specifically for charging-related heat dissipation, allowing the active system to focus on critical components while the passive system handles charging thermal loads independently.
Solution Approach 2:
The passive heat exchanger operates autonomously without requiring external power or control systems. It uses natural convection and phase change of refrigerant to dissipate heat generated during charging, making the system self-sufficient and eliminating the need for additional active components during charging operations.
2Temperature
If active thermal management components are added for charging operations, then heat dissipation capability is improved, but device complexity increases
Solution Approach 1:
The patent extracts the thermal management function for charging operations from the main active thermal management system. A separate passive heat exchanger is implemented specifically for charging-related heat dissipation, allowing the active system to focus on critical components while the passive system handles charging thermal loads independently.
Solution Approach 2:
The patent replaces mechanical active cooling components (fans, pumps) with a passive heat exchanger that utilizes natural convection and phase change mechanisms. This substitution eliminates complex mechanical systems while maintaining effective heat dissipation capability for charging operations.
3Temperature
If a passive heat exchanger is positioned in the airflow path of the radiator fan, then heat dissipation efficiency is improved, but thermal load on the existing coolant loop increases
Solution Approach 1:
The patent segments the thermal management system into distinct functional zones: the active coolant loop handles critical components, while the passive heat exchanger with its own refrigerant loop handles charging-related heat dissipation. This segmentation prevents thermal load mixing and allows independent optimization of each subsystem.
Solution Approach 2:
The passive heat exchanger acts as an intermediary thermal management system positioned in the airflow path. It uses a separate refrigerant loop that does not interfere with the main coolant loop, effectively dissipating charging heat while preserving thermal resources for other critical 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 solution effectively manages thermal energy generated during vehicle charging without additional active components, preserving thermal resources for other critical components and minimizing disruptions to existing thermal management systems.
Implementation Method 1
a cold plate containing a refrigerant and in physical contact with at least one of the power electronics unit or the charging coil
Implementation Method 2
the liquid-state refrigerant to a vapor-state refrigerant
Implementation Method 3
the second refrigerant convectively flows between the cold plate and the condenser
Implementation Method 4
a condenser in fluid communication with the cold plate and arranged in an airflow path of the fan
Implementation Method 5
dissipating, via the condenser, the at least the portion of the thermal energy from the vapor-state refrigerant
Data Source
AI summary
Operations associated with charging a vehicle may generate thermal energy. A passive thermal management solution may dissipate the thermal energy without requiring additional active components and without adding significant thermal loads to an existing thermal management system. In some examples, a passive heat exchanger may include a cold plate coupled to power electronics. In addition, the passive heat exchanger may include a condenser that is fluidly coupled to the cold plate and is positioned in an airflow path.