Range Extender Thermal Coupling for EV Cabin Waste Heat Transfer
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Solution Overview
Problem
Electric vehicles with modular range extenders face inefficiencies in utilizing waste heat for cabin heating, as existing designs do not effectively harness and transfer the waste heat generated by the range extender module to the cabin heating circuit, leading to reduced range capacity during heating demands.
Innovation Solution
A system that thermally couples the cooling circuit of the range extender module to the heating circuit of the cabin module using thermal coupling elements, allowing waste heat from the range extender module to be transferred via thermal contact conductance, thereby enhancing cabin heating without depleting the vehicle's energy reserves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If waste heat from the range extender module is not transferred to the cabin heating circuit, then the cabin heating system can operate independently using battery power, but the vehicle's range capacity is reduced during heating demands
Solution Approach 1:
The patent converts the harmful waste heat generated by the range extender module into a beneficial resource for cabin heating. By implementing thermal coupling elements that transfer waste heat from the range extender cooling circuit to the cabin heating circuit, the system eliminates energy waste and reduces the battery's energy consumption during heating operations, thereby extending vehicle range capacity.
Solution Approach 2:
The patent merges the range extender cooling circuit with the cabin heating circuit through thermal coupling elements. This integration allows the two previously separate thermal systems to work together, where the waste heat from the range extender directly contributes to cabin heating, creating a unified thermal management system that improves overall energy efficiency.
2Adaptability or versatility
If the range extender module is integrated into the rear axle module, then the vehicle platform can be efficiently converted without a range extender, but the waste heat at the rear is not utilized for cabin heating
Solution Approach 1:
The patent introduces thermal coupling elements as intermediary components between the rear axle module containing the range extender and the front cabin heating circuit. These coupling elements act as mediators that enable thermal energy transfer across the vehicle's length, allowing the rear waste heat to reach and heat the front cabin while preserving the modular rear axle integration.
3Loss of energy
If thermal coupling elements are implemented to transfer waste heat, then energy efficiency is improved, but the system complexity increases
Solution Approach 1:
The patent segments the thermal coupling system into distinct modular components: a first thermal coupling element connected to the range extender cooling circuit and a second thermal coupling element connected to the cabin heating circuit. This segmentation allows for easier manufacturing, assembly, and maintenance while achieving effective waste heat transfer through the coordinated operation of separate thermal coupling elements.
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 conserves cabin module energy by utilizing waste heat for heating, extending the vehicle's range by reducing the need for energy consumption during heating requirements, especially in winter months, and improves the overall efficiency of the vehicle's heating system.
Implementation Method 1
allowing waste heat from the range extender module to be transferred via thermal contact conductance
Data Source
AI summary
A system for transferring waste heat from a range extender module of an electric vehicle to a cabin module includes a cooling circuit in the range extender module and a heating circuit of the cabin module. The cooling circuit is thermally coupled to the heating circuit. The cooling circuit includes a thermal coupler and the heating circuit includes a corresponding thermal coupler. The thermal coupler of the cabin module heating circuit may be disposed at the rear of the cabin module, and the thermal coupler for the cooling circuit of the range extender module may be disposed at the front of the range extender module. The thermal coupler of the range extender module may be longitudinally adjustable.