System for controlling the temperature of an electrical energy storage device
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Solution Overview
Problem
Existing systems for controlling the temperature of electrical energy storage devices in vehicles are heavy, which affects the center of gravity and load capacity, necessitating a weight reduction solution.
Innovation Solution
The system incorporates a support structure with molded components made of foamed plastic, such as expanded polypropylene, to create lightweight and precise holders for components like the coolant control device, first coolant cooler, and refrigerant compressor, along with thermal insulation and secure mounting mechanisms to prevent incorrect installation and condensate formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional metal holders and mounting structures are used for the coolant control device and coolant cooler, then structural strength and stability are ensured, but the overall system weight increases significantly
Solution Approach 1:
The patent employs foamed plastic material with a cellular structure to create holders and mounting structures. The foam material provides adequate mechanical strength while significantly reducing weight compared to solid metal structures. The cellular structure of the foam maintains structural integrity while achieving weight reduction for the coolant control device and coolant cooler assembly.
Solution Approach 2:
The patent uses composite construction by combining foamed plastic material with metal components strategically. The holders are made of foamed plastic for weight reduction, while metal elements are used only where high strength is absolutely necessary, creating a hybrid composite structure that optimizes the strength-to-weight ratio for the temperature control system.
2Weight of moving object
If foamed plastic molded components are used to create holders, then weight is reduced and precision is maintained, but manufacturing complexity increases
Solution Approach 1:
The patent integrates multiple functions into a single molded holder component. The foamed plastic holder simultaneously provides mounting functionality, thermal insulation, and structural support for the coolant control device and coolant cooler. This consolidation reduces the number of separate parts and assembly steps, offsetting the manufacturing complexity of the molded component itself.
Solution Approach 2:
The molded holder component serves multiple purposes: it acts as a mounting structure, provides thermal insulation between components, maintains precise positioning, and reduces overall system weight. This multi-functionality eliminates the need for separate insulation materials and mounting brackets, simplifying the overall manufacturing process despite the complexity of creating the molded component.
3Measurement precision
If the coolant control device and coolant cooler are integrated with thermal insulation, then temperature control precision is improved, but device complexity increases
Solution Approach 1:
The patent combines the thermal insulation function with the structural holder component. The foamed plastic material that forms the holder also provides thermal insulation, eliminating the need for separate insulation layers or components. This integration maintains precise temperature control while avoiding the complexity of multi-layer insulation systems.
Solution Approach 2:
The use of foamed plastic creates a composite structure where the material itself provides both structural support and thermal insulation properties. This composite approach achieves precise temperature control by insulating the coolant control device and coolant cooler, while the integrated nature of the foam material avoids adding separate insulation components that would increase system 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
This design achieves a significant weight reduction while maintaining precision and efficiency in temperature control, allowing for on-demand cooling and heating of the energy storage device, enhancing vehicle performance and load capacity.
Implementation Method 1
The molded component formed in this way can define, for example, a flow path and/or a holder for an element of the system... A favorable option provides that the foamed plastic is expanded polypropylene (EPP)... A further particularly favorable option provides that the receptacle for the coolant control device thermally insulates the coolant control device
Implementation Method 2
A system for controlling the temperature of an electrical energy storage device comprises a coolant circuit (12), through which a liquid coolant (14) flows... a first coolant cooler (24), through which the liquid coolant (14) and a refrigerant (18) can flow... so that the coolant can absorb heat from the electrical energy storage device or dissipate it to the electrical energy storage device
Implementation Method 3
a refrigerant circuit (16), through which refrigerant (18) flows and thus forms a part of a heat pump. The coolant can thus additionally be cooled down
Data Source
AI summary
A system for controlling a temperature of an electrical energy storage device may include a coolant circuit through which a coolant is flowable, a refrigerant circuit through which a refrigerant is flowable, a first coolant cooler, a support structure, and at least one molded component. The coolant circuit may be thermally coupled to the electrical energy storage device such that heat is at least one of (i) absorbable from the electrical energy storage device via the coolant and (ii) dissipatable to the electrical energy storage device via the coolant. The refrigerant circuit may be configured as part of a heat pump. The first coolant cooler may be configured to transfer heat between the coolant and the refrigerant. The at least one molded component may be structured separately from the support structure and may include a foamed plastic.