Vehicle Thermal Layout Using One Chiller and Valve-Switched Coolant Paths

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Solution Overview

Problem

Existing thermal management systems for electric vehicles require separate cooling systems for battery modules and electrical components, leading to space restrictions and increased power consumption, while also needing efficient waste heat utilization and interior heating solutions.

Innovation Solution

A thermal management system utilizing a single chiller with refrigerant and coolant heat-exchange, combined with a battery heater for selective coolant heating, allows for efficient temperature adjustment of battery modules and vehicle interiors, while simplifying system layout and reducing manufacturing costs through valve-controlled coolant flow lines.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate cooling systems are applied to adjust the temperature of electrical components and battery module, then temperature control capability is improved, but system complexity and space requirements increase

Engineering Contradiction:

Improvetemperature control capabilityVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines separate cooling systems for electrical components and battery modules into a single integrated thermal management system. The coolant circulation system serves both the electrical component heat exchanger and battery module heat exchanger through a unified coolant flow path controlled by valve modules, reducing system complexity while maintaining independent temperature control capability for each component.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The thermal management system is designed with multi-functionality to handle different operating modes: cooling electrical components, cooling battery modules, heating the vehicle interior using waste heat from battery heating, and various combinations thereof. The valve modules enable the system to switch between different coolant flow configurations to achieve different thermal management objectives.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If capacity of cooling systems is increased, then temperature adjustment capability is improved, but power consumption increases

Engineering Contradiction:

Improvetemperature adjustment capabilityVSAvoidpower consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The system converts waste heat from battery module heating operations into a useful resource for vehicle interior heating. The battery heater heats the coolant, and the heated coolant is then directed to the cabin heater to warm the vehicle interior, thereby converting what would be wasted thermal energy into a beneficial heating source and reducing overall energy consumption.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The thermal management system utilizes its own operational byproducts (heated coolant from battery heating) to serve additional functions (cabin heating). This self-service approach allows the system to meet multiple thermal demands while minimizing external energy input, as the heat generated for battery temperature management is reused for passenger comfort.

Inventive Principle:

Principle #25Self-service

3Reliability

If separate cooling systems are applied, then temperature control precision is improved, but space requirements increase

Engineering Contradiction:

Improvetemperature control precisionVSAvoidspace requirements

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The patent merges multiple coolant circulation loops into a single integrated system where the coolant flows through heat exchangers for both electrical components and battery modules in sequence or parallel configurations controlled by valve modules. This consolidation reduces the total space required for radiators, pumps, and coolant reservoirs while maintaining the ability to independently regulate temperatures of different components through electronic valve control.

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 improves overall efficiency by efficiently managing battery module temperatures, enhancing vehicle performance, reducing manufacturing costs, and optimizing space utilization, while enabling effective heating of the vehicle interior.

Implementation Method 1

one chiller where the refrigerant and the coolant heat-exchange with each other

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Implementation Method 2

a battery heater for selectively heating the coolant

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 3

adjusting the temperature of a battery module by using one chiller where the refrigerant and the coolant heat-exchange with each other

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS20250144975A1Thermal management system for a vehicle

Publication Date: 2025.05.08 HYUNDAI MOTOR CO LTD

AI summary

A thermal management system for a vehicle may adjust the temperature of a battery module by using one chiller where the refrigerant and the coolant heat-exchange with each other and a battery heater for selectively heating the coolant, perform heating of the vehicle interior by using the coolant heated by the battery heater, simplify a layout of the system, and reduce manufacturing costs by forming a plurality of coolant flowing lines by two valves according to a selected mode of the vehicle.