Retrofit Fuel Cell Module for EV Battery Heating and Range
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Solution Overview
Problem
Existing electric vehicles face challenges with limited range, especially at low temperatures, due to inefficient battery heating and the need for additional heating systems, which increase weight, cost, and complexity.
Innovation Solution
A retrofit system comprising a fuel cell and a fuel tank module that can be installed in vehicles to provide both thermal and electrical energy, allowing for efficient battery heating and extended range, with the option for temporary or permanent installation based on temperature needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fuel cell system is permanently installed in the vehicle for heating the battery and passenger cabin, then the vehicle can operate efficiently at low temperatures, but the vehicle weight increases and production costs rise
Solution Approach 1:
The patent applies the dynamics principle by making the fuel cell system movable rather than permanently fixed. The system can be attached to the vehicle when cold weather operation is needed and removed when not needed, allowing the vehicle weight to vary dynamically based on operational requirements. This resolves the contradiction by providing cold temperature capability only when necessary, rather than carrying the weight permanently.
Solution Approach 2:
The patent segments the heating system into a separate, detachable fuel cell module that can be independently attached or removed from the vehicle. This segmentation allows the vehicle to have the heating capability on demand without it being an integral permanent part of the vehicle structure, thus reducing the average weight burden while maintaining reliability when needed.
2Reliability
If a fuel cell system is permanently installed in the vehicle for heating, then the battery can be heated efficiently at low temperatures, but the production costs and maintenance effort increase
Solution Approach 1:
The dynamic attachment and detachment of the fuel cell system allows manufacturers to produce base vehicles without the expensive fuel cell infrastructure, reducing production costs. When cold weather operation is required, the system can be added as an optional accessory, spreading the manufacturing cost only to those vehicles that need it, while maintaining battery heating efficiency when the system is attached.
Solution Approach 2:
The fuel cell system is designed as a universal module that can be attached to different vehicle types and used for multiple purposes (heating battery, heating passenger cabin, potential power generation). This multi-functionality justifies the production cost by providing multiple benefits from a single add-on system, making it economically viable for manufacturers to produce vehicles with this optional capability.
3Temperature
If the vehicle battery is used to power heating systems for the passenger cabin and vehicle components, then the vehicle can be heated, but the vehicle range decreases
Solution Approach 1:
The fuel cell system serves itself by using its own chemical energy storage (hydrogen fuel) to generate the thermal energy needed for heating, rather than drawing from the vehicle battery. The fuel cell converts chemical energy directly to electrical energy and thermal energy, providing a self-sufficient heating source that preserves the battery's energy for propulsion, thus maintaining vehicle range while providing heating capability.
Solution Approach 2:
The heating function is extracted from the battery system and transferred to the independent fuel cell system. By taking the heating load off the battery, the battery's energy reserves are preserved for vehicle propulsion, thereby maintaining vehicle range. The fuel cell system independently handles the heating requirement through its own fuel supply.
4Duration of action of moving object
If hybrid drives with combustion engine and electric drive are used, then the vehicle can achieve extended range, but the device complexity increases
Solution Approach 1:
The patent extracts the power generation function from the complex hybrid drive system and places it in a simpler, dedicated fuel cell module. Instead of integrating fuel cell technology into a complex hybrid architecture with multiple drives and energy storage devices, the fuel cell is used in its simplest form - as a stationary power and heat source that can be attached or removed, thereby extending range without adding drive system complexity.
Solution Approach 2:
The patent replaces the mechanical complexity of hybrid drive systems with a simpler electrochemical system. Instead of managing multiple mechanical drives, transmissions, and coupled energy storage systems, the fuel cell provides direct electrochemical conversion of fuel to electrical and thermal energy, substituting mechanical complexity with a more straightforward energy conversion process that achieves extended range with less complexity.
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
The system enhances vehicle range by optimizing energy use, reduces production and maintenance costs, and provides versatile applications beyond vehicle use, including emergency power and heating solutions.
Implementation Method 1
In a fuel cell, the energy stored chemically in a fuel, such as hydrogen, is converted directly into electrical energy and then into mechanical work.
Implementation Method 2
a fuel cell operated with fuel from said tank for heating the passenger cabin, vehicle components and/or vehicle battery of said vehicle
Implementation Method 3
In electric vehicles, the energy stored in a battery is converted into mechanical work via an electric drive.
Data Source
AI summary
The invention relates to an electrically operated vehicle containing an electrically rechargeable vehicle battery for supplying an electric drive for moving the vehicle; a tank for receiving a liquid or gaseous fuel; and a fuel cell which is operated using fuel from the tank for heating a passenger compartment, vehicle components, and/or the battery of the vehicle. The invention is characterized in that the tank and the fuel cell form modules with which the vehicle is retrofitted.