Portable Charger Cooling With Liquid Coolant and Refrigerant Loop
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Solution Overview
Problem
Existing field operable electric charger systems face challenges in efficiently managing thermal energy generated by power conversion assemblies due to their portable and mobile nature, which is not adequately addressed by fixed cooling systems.
Innovation Solution
A cooling arrangement incorporating a liquid coolant circuit and an intermediate refrigerant circuit with a vapor compression cycle, utilizing a heat exchanger to transfer thermal energy from the liquid coolant to refrigerant, and discharging it to the ambient environment through a radiator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed cooling system is used for the power conversion assembly, then thermal management is simplified, but the system becomes unsuitable for portable and mobile operations
Solution Approach 1:
The cooling system is divided into separate functional modules: a refrigerant circuit with compressor and condenser, a liquid coolant circuit with coolant pump and heat exchanger, and thermal coupling elements. This segmentation allows each component to be independently optimized and reconfigured for different portability requirements while maintaining effective thermal management of the power conversion assembly
Solution Approach 2:
A liquid coolant circuit serves as an intermediary between the power conversion assembly and the refrigerant circuit. The coolant absorbs heat from the power conversion components and transfers it to the refrigerant via a heat exchanger, enabling flexible thermal management without direct coupling between the power conversion and refrigeration systems
2Reliability
If thermal energy is efficiently dissipated from the power conversion assembly, then system reliability improves, but system size and weight increase
Solution Approach 1:
The refrigerant circuit utilizes phase transitions of the refrigerant (evaporation and condensation) to efficiently transfer and dissipate thermal energy. The compressor compresses refrigerant vapor, the condenser condenses it releasing heat, and this phase-change-based heat transfer achieves high reliability thermal management with relatively compact and lightweight components suitable for mobile applications
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
Effectively manages thermal energy by maintaining efficient cooling of power conversion components, reducing system size and weight, and minimizing material compatibility issues.
Implementation Method 1
a liquid coolant circuit having a coolant pump directing the liquid coolant to the power conversion assembly
Implementation Method 2
To exchange thermal energy between the liquid coolant and the refrigerant, the charger cooling system includes a heat exchanger disposed between the liquid coolant circuit and the refrigerant circuit
Implementation Method 3
an intermediate refrigerant circuit has a compressor directing a refrigerant to a condenser and a throttle valve receiving refrigerant from the condenser
Data Source
AI summary
A field operable electric charger system includes a charger cooling arrangement having a liquid coolant circuit and an intermediate refrigerant circuit. The liquid coolant system directs a liquid coolant to a power conversion unit that converts electrical recharging power to for delivery and storing in a plurality of rechargeable electrical storage batteries. The liquid coolant absorbs thermal energy from the power conversion unit and a heat exchanger transfers the thermal energy from the liquid coolant to a refrigerant circulating in the refrigerant circuit. The thermal energy is discharge from the refrigerant to the ambient environment through a radiator.