Segmented Deaeration Device for Multi-Loop EV Thermal Management
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Solution Overview
Problem
Thermal management systems in electrified vehicles face challenges in effectively removing entrained air from multiple cooling loops, leading to inefficient fluid circulation and potential heat transfer issues between components.
Innovation Solution
A deaeration device is fluidly connected to multiple cooling loops, featuring separate regions and swirl flow paths to induce vortices, which helps in deaerating the fluid and minimizing coolant and heat transfer between loops, with a standpipe and deaeration port configuration to manage air removal and fluid circulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single deaeration device is used for multiple cooling loops, then device complexity is reduced, but air removal effectiveness deteriorates due to air pockets forming in interconnected loops
Solution Approach 1:
The deaeration device is segmented into multiple independent chambers (first chamber for first cooling loop, second chamber for second cooling loop), each with separate deaeration ports. This segmentation allows independent air removal from each cooling loop while using a single integrated device structure, resolving the contradiction between device simplicity and air removal effectiveness.
2Productivity
If coolant is allowed to transfer between cooling loops for thermal balance, then thermal management efficiency improves, but heat transfer between loops with different thermal energy levels causes temperature control issues
Solution Approach 1:
The deaeration device acts as an intermediary component that selectively allows coolant transfer between cooling loops only when necessary for air removal, while preventing uncontrolled heat transfer. The one-way valve mechanism enables controlled fluid movement without allowing thermal equilibrium between loops with different temperature requirements, thus maintaining temperature control precision while improving thermal management efficiency.
3Reliability
If deaeration ports are positioned at highest points of cooling loops, then air removal effectiveness improves, but device complexity increases due to elevated component placement requirements
Solution Approach 1:
The deaeration device introduces a vertical dimension to the cooling loop system by positioning chambers and deaeration ports at different elevations. The first chamber is positioned higher than the second chamber, with deaeration ports at their respective highest points, allowing effective air removal through gravitational separation without requiring complex external positioning of individual loop 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
The deaeration device effectively removes air from the fluid loops, ensuring proper circulation and maintaining distinct thermal energy levels across components, reducing heat and coolant transfer, and enhancing the thermal management system's efficiency.
Implementation Method 1
a first swirl flow path between the first inlet port and the first outlet port extends over a range that is configured to induce the formation of a first vortex
Implementation Method 2
the first inlet port is rotationally offset from the first outlet port, and the second inlet port is rotationally offset from the second outlet port
Implementation Method 3
the volume of air that is deaerated from the first fluid loop passes through a standpipe prior to entering the deaeration port
Data Source
AI summary
This disclosure details thermal management systems with two or more cooling loops for thermally managing multiple components of an electrified vehicle. An exemplary thermal management system may include a deaeration device that is fluidly connected to two or more cooling loops (e.g., a traction battery pack loop, a power electronics loop, etc.). The deaeration device is configured to allow for deaeration of the two or more cooling loops while reducing coolant transfer and heat transfer between the two or more cooling loops.