Shared EV Thermal Circuit for Bidirectional Battery Heat Exchange
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Solution Overview
Problem
Existing thermal management systems for electrified vehicles are inefficient in exchanging heat between new secondary batteries and other vehicle components, leading to wasted heat and suboptimal performance.
Innovation Solution
A shared thermal management system that utilizes a battery system with high-temperature capable battery cells and a shared thermal circuit with a working fluid, switches, and a control system to efficiently couple the battery system with other vehicle components like the internal combustion engine, allowing for bidirectional heat exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional thermal management systems are used to cool or heat vehicle components, then components can maintain their preferred operating temperature ranges, but heat exchange efficiency between battery system and other components is insufficient leading to wasted heat energy
Solution Approach 1:
The patent merges the thermal management circuits of the battery system and internal combustion engine into a single shared thermal circuit. This allows heat generated by the engine to be directly transferred to the battery for heating, and battery heat to be used for engine cooling, eliminating the need for separate thermal management systems and significantly reducing heat energy waste.
Solution Approach 2:
The patent converts the waste heat generated by the internal combustion engine, which would normally be discarded, into a useful resource for heating the battery system. Similarly, excess heat from the battery system is converted into a cooling resource for the engine, transforming harmful waste heat into beneficial thermal energy exchange.
2Reliability
If separate thermal management systems are used for battery system and other vehicle components, then each component can be independently controlled, but system complexity and cost increase
Solution Approach 1:
The shared thermal circuit is designed to serve multiple functions: it can heat the battery using engine waste heat, cool the battery when overheating, cool the engine using battery heat, and provide climate control support. This multi-functional design eliminates the need for separate thermal management systems while maintaining reliable temperature control for all components through a single integrated system.
Solution Approach 2:
By combining the thermal management functions for the battery system, internal combustion engine, and other vehicle components into a single shared thermal circuit, the patent reduces system complexity and component count while maintaining the ability to independently control each component's temperature through electronic control valves and pumps.
3Object-affected harmful factors
If conventional batteries operating at lower temperatures are used, then battery safety is improved, but heat from internal combustion engine cannot be effectively utilized for battery heating
Solution Approach 1:
The patent specifies that the battery system operates at elevated temperatures (40°C to 150°C, preferably 60°C to 120°C) compared to conventional batteries. This parameter change in operating temperature enables the battery to effectively utilize waste heat from the internal combustion engine while maintaining safety through the shared thermal circuit's controlled heat exchange mechanisms.
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 system enables faster and more efficient heating and cooling of vehicle components, reduces system complexity and cost, and improves battery performance by optimizing operating temperatures, thereby enhancing overall vehicle efficiency and range.
Implementation Method 1
a shared thermal circuit thermally coupling the battery system to other vehicle components, wherein the thermal circuit includes a working fluid
Implementation Method 2
at least one external heat exchanger
Data Source
AI summary
This patent application is directed to thermal management systems of vehicles with an electric powertrain. More specifically, the battery system and one or more powertrain components and/or cabin climate control components of a vehicle share the same thermal circuit as the battery module through which heat can be exchanged between the battery module and one or more powertrain or climate control components as needed.