Vehicle Battery Cooling Circuit Using Pump-Driven Refrigerant Flow
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Solution Overview
Problem
Existing cooling devices for vehicle batteries, particularly in rail vehicles, are energy-intensive and require additional components, increasing manufacturing costs, weight, and space, with existing solutions not suitable for high-pressure refrigerant CO2 and inefficient at high ambient temperatures.
Innovation Solution
A cooling device with a refrigerant circuit and coolant circuit coupled via a heat exchanger, featuring a condenser, refrigerant pump, expansion valve, evaporator, and compressor, with a bypass system allowing the compressor to be switched off at low temperatures, using a sensor to control refrigerant flow and optimize cooling capacity, and utilizing common refrigerants like R134a.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a refrigeration system based on compression refrigeration principle is used to cool battery cells below ambient temperatures, then cooling performance is improved, but energy consumption increases significantly
Solution Approach 1:
The system changes the operating parameters of the refrigeration cycle by using a refrigerant pump to circulate refrigerant instead of relying solely on compressor-driven flow. This allows the system to achieve effective cooling with lower energy input by optimizing the refrigerant circulation parameters
Solution Approach 2:
The invention replaces the traditional compressor-based refrigerant circulation with a pump-based system. This mechanical substitution reduces energy consumption while maintaining the ability to cool battery cells below ambient temperatures
2Temperature
If additional cooler components are added to enable cooling without refrigeration unit operation, then cooling capability is improved, but device complexity and manufacturing costs increase
Solution Approach 1:
The refrigerant pump serves multiple functions: it circulates refrigerant during both refrigeration mode and ambient cooling mode, replacing the need for separate cooling components. This multi-functionality reduces device complexity while maintaining cooling capability across different operating conditions
Solution Approach 2:
The invention merges the refrigerant circulation function with the cooling function by using the same pump and heat exchanger components for both refrigeration-based cooling and ambient temperature cooling, eliminating the need for additional separate cooler components
3Productivity
If CO2 refrigerant is used in high-pressure applications, then cooling efficiency is improved, but pressure resistance requirements and system tightness become technically impossible or require great effort
Solution Approach 1:
The system changes the pressure parameters by using a refrigerant pump instead of a high-pressure compressor, operating at lower pressures while maintaining cooling efficiency. This parameter change eliminates the need for extreme pressure resistance and tightness requirements
4Temperature
If radiator is constantly circulated by air to enable cooling at low temperatures, then cooling performance is improved, but space requirements and manufacturing costs increase
Solution Approach 1:
The invention replaces air-based cooling with a closed-loop liquid refrigerant circulation system using a pump. This substitution eliminates the need for large radiators and constant air circulation, reducing space requirements while maintaining cooling performance
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
Enables energy-efficient cooling of vehicle batteries with minimal equipment, reducing energy consumption and space requirements, while maintaining optimal cooling performance across varying ambient conditions.
Implementation Method 1
a refrigerant circuit and a coolant circuit, which are coupled via a heat exchanger
Implementation Method 2
a condenser, a refrigerant pump arranged downstream thereof
Implementation Method 3
an evaporator arranged even further downstream, which is designed as a heat exchanger with the coolant circuit
Implementation Method 4
a refrigerant pump arranged downstream thereof
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The cooling device according to the invention comprises a refrigerant circuit and a coolant circuit coupled to it. The refrigerant flow can be controlled by means of a sensor, which in turn controls a valve or a refrigerant pump. At low ambient temperatures, the compressor is switched off, thus enabling efficient cooling, particularly for a vehicle battery.