Vehicle Thermal Flow Switching for Battery Heating Precision

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Solution Overview

Problem

Electrified vehicles face challenges in effectively utilizing heat generated by drive devices like inverters and motors for both heating purposes and efficiently heating energy storage devices, such as batteries, especially in scenarios where engine waste heat is not available.

Innovation Solution

A thermal management system that includes multiple flow paths for heat mediums, a radiator, a chiller, and a switching device to control the circulation of heat mediums between these components, allowing for efficient heating of energy storage devices while utilizing heat generated by drive devices, and also includes a refrigeration cycle for cabin heating.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If the thermal management system uses a single integrated flow path for both battery heating and drive device heat dissipation, then the system structure is simplified, but the heating efficiency of the battery is reduced due to heat loss to the drive device

Engineering Contradiction:

Improvesystem structureVSAvoidbattery temperature

Core Design Contradiction:

Device complexityVSTemperature

Solution Approach 1:

The thermal management system is divided into separate flow paths: a first flow path for battery heating and a second flow path for drive device heat dissipation. The switching device selectively connects these flow paths based on operational requirements, allowing independent thermal management of each component and preventing heat loss from the battery heating process.

Inventive Principle:

Principle #1Segmentation

2Productivity

If the system prioritizes battery heating by isolating the first flow path, then heating efficiency is improved, but the ability to utilize waste heat from the drive device is reduced

Engineering Contradiction:

Improveheating efficiencyVSAvoidwaste heat utilization

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The switching device dynamically reconfigures the thermal management system based on real-time operational conditions. When battery heating is prioritized, the first flow path is isolated. When waste heat utilization is beneficial, the system switches to allow heat transfer from the drive device to the battery, optimizing energy efficiency under different operating scenarios.

Inventive Principle:

Principle #15Dynamics

3Loss of energy

If the system allows heat exchange between the first and second flow paths, then waste heat from the drive device can be utilized, but the temperature control precision of the battery is reduced

Engineering Contradiction:

Improvewaste heat utilizationVSAvoidtemperature control

Core Design Contradiction:

Loss of energyVSMeasurement precision

Solution Approach 1:

The system extracts the battery heating function into a separate first flow path that can be isolated from the drive device heat dissipation path. This separation allows the battery to receive precisely controlled heating without being affected by the variable thermal conditions of the drive device, while still enabling waste heat utilization when needed through controlled switching.

Inventive Principle:

Principle #2Taking out (Extraction)

4Measurement precision

If the system uses multiple independent flow paths for battery and drive device thermal management, then temperature control precision is improved, but the system complexity and number of components increases

Engineering Contradiction:

Improvetemperature controlVSAvoidnumber of flow paths

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The thermal management system merges the battery heating flow path and drive device heat dissipation flow path into a unified system controlled by a single switching device. This allows the system to function as a single integrated unit with simplified control logic, while still providing the thermal isolation and precision control benefits of separate flow paths when needed.

Inventive Principle:

Principle #5Merging (Combining)

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 achieves effective use of heat generated by drive devices for both battery heating and vehicle cabin heating, ensuring efficient thermal management and reduced power consumption during heating operations.

Implementation Method 1

an energy storage device configured to exchange heat with the heat medium flowing through the first flow path

Methodology Applied