PCM Thermal Storage for EV Battery Heating Without Power Drain
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Solution Overview
Problem
Electric drive systems in vehicles face inefficiencies due to the need for excessive electrical consumption for heating and cooling battery systems, which depletes stored energy and reduces system performance, especially in extreme temperature conditions.
Innovation Solution
Incorporating a phase change material (PCM) energy storage unit within the electric drive system, coupled with a fluid system that collects and stores heat from the drive and power conversion units, allowing for selective heating and cooling of the battery system without draining battery power, using a thermal management system that includes a cooling unit and control valves to manage thermal energy efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If electric powered heaters are used to heat battery systems, then heating function is achieved, but electrical power is depleted and efficiency is reduced
Solution Approach 1:
The system uses the battery system's own waste heat from operation to heat the battery during cold conditions, eliminating the need for external electric heating. The thermal management system recycles heat that would otherwise be lost, allowing the battery to maintain optimal temperature using its own thermal energy.
Solution Approach 2:
The system employs phase change material (PCM) that undergoes phase transition between solid and liquid states to store and release thermal energy. When the PCM melts, it absorbs heat; when it freezes, it releases heat. This phase transition mechanism provides efficient thermal storage and release without requiring continuous electrical power input.
2Temperature
If conventional radiator devices are used to cool battery systems, then cooling function is achieved, but system complexity increases
Solution Approach 1:
The thermal management system serves multiple functions: it cools the battery during high-temperature operation, stores excess heat in the PCM, and releases stored heat when the battery needs heating. This multi-functional approach eliminates the need for separate heating and cooling systems, reducing overall system complexity.
Solution Approach 2:
The system merges the cooling function with thermal energy storage and heating functions into a single integrated thermal management system. The fluid circulation system, PCM storage unit, and battery thermal management are combined into one system that handles both heating and cooling needs.
3Loss of energy
If waste heat is not recovered from drive and power conversion units, then heat is lost to environment, but thermal energy storage capability is underutilized
Solution Approach 1:
The system converts waste heat from the drive unit and power conversion system, which would otherwise be lost to the environment, into useful thermal energy. The PCM storage unit captures this waste heat and stores it for later use in heating the battery or other thermal management needs, turning a harmful energy loss into a beneficial resource.
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 enables effective heating and cooling of electric drive systems without significant electrical consumption, maintaining battery efficiency and extending the operational range of electric vehicles by optimizing thermal management.
Implementation Method 1
An energy storage unit, containing at least one phase change material, is provided and configured to store and/or release heat
Implementation Method 2
The fluid system is configured to selectively store the heat in the energy storage unit in the phase change material
Data Source
AI summary
An electric drive system with heat management includes an electric drive unit coupled with a battery system and a power conversion system. An energy storage unit contains at least one phase change material and is configured to manage thermal energy. A cooling system is configured to exchange heat and has a fluid system extending through the drive unit, the battery system, the power conversion system, the energy storage unit, and the cooling system. The fluid system configured to collect heat from the drive unit, the battery system and the power conversion system; selectively expel the heat through the cooling system; selectively store the heat in the energy storage unit in the at least one phase change material; and selectively supply heat from the energy storage unit to the battery system.