A new energy vehicle thermal management system based on R290 refrigerant

Abstract

This invention relates to a thermal management system for new energy vehicles based on R290 refrigerant. It includes an air conditioning module using R290 refrigerant as the medium, a passenger compartment module, an external heat exchange module, and a battery module. The air conditioning module, in the order of the medium flow, includes: a compressor, a first flow channel of a first liquid heat exchanger, a liquid receiver-drier, an electronic expansion valve, and a first flow channel of a second liquid heat exchanger. This thermal management system uses R290 as the refrigerant, ensuring it is only used in the air conditioning module, reducing its dosage. The refrigerant is also centrally distributed for easy protection. Heat is released through the first liquid heat exchanger and absorbed through the second. Furthermore, the passenger compartment module, external heat exchange module, and battery module are combined to achieve a dual-medium thermal management system. This allows the introduction of the more thermally efficient R290 refrigerant into the vehicle's thermal management system. Additionally, the optimized pipes and valves can be integrated into valve modules, helping to reduce space occupancy.

Description

Technical Field

[0001] This invention belongs to the field of new energy vehicle air conditioning technology, specifically relating to a new energy vehicle thermal management system based on R290 refrigerant. Background Technology

[0002] To reduce air conditioning energy consumption, especially heating energy consumption, pure electric new energy vehicles often incorporate complex heat pump circuits to recover waste heat from the motor and battery. Currently, new energy vehicles commonly use R134a or R1234yf as refrigerants. Compared to these refrigerants, R290 refrigerant offers better cooling efficiency, especially maintaining considerable heating capacity even at ultra-low temperatures (-20℃). However, R290 refrigerant is flammable and explosive. Directly replacing common refrigerants with R290 in complex heat pump circuits poses significant safety hazards due to the large amount required. Therefore, a thermal management system that can utilize R290 refrigerant is urgently needed. Summary of the Invention

[0003] The purpose of this invention is to provide a thermal management system for new energy vehicles based on R290 refrigerant in order to solve the above problems.

[0004] The present invention achieves the above objectives through the following technical solutions:

[0005] A new energy vehicle thermal management system based on R290 refrigerant, characterized in that: it includes an air conditioning module using R290 refrigerant as the medium, and also includes a passenger compartment module, an external heat exchange module, and a battery module. The air conditioning module includes, in sequence according to the flow direction of the medium circuit: a compressor, a first flow channel of a first liquid heat exchanger, a liquid storage drying bottle, an electronic expansion valve, and a first flow channel of a second liquid heat exchanger.

[0006] The second flow channel of the first liquid heat exchanger is used to heat the crew cabin module or battery module, or to dissipate heat to the external environment through the external heat exchange module. The second flow channel of the second liquid heat exchanger is used to cool the crew cabin module or battery module, or to absorb heat from the external environment through the external heat exchange module.

[0007] As a further optimization of the present invention, when the second flow channel of the first liquid heat exchanger is used to dissipate heat to the external environment, its circuit sequentially includes the outlet of the first three-way valve B, the outlet of the second three-way valve B, the expansion tank, the external hot water tank, the outlet of the seventh three-way valve A, the cooling flow channel of the motor, the outlet of the fifth three-way valve A, and the first medium pump. When the second flow channel of the second liquid heat exchanger is used to absorb heat to the external environment, its circuit sequentially includes the outlet of the third three-way valve A, the outlet of the fourth three-way valve A, the expansion tank, the external hot water tank, the outlet of the seventh three-way valve A, the cooling flow channel of the motor, the outlet of the fifth three-way valve B, and the second medium pump. The external heat exchange module is used to exchange heat with the external environment through the expansion tank and the external hot water tank. The first liquid heat exchanger and the second liquid heat exchanger share the same external heat exchange module in different time periods through the above-mentioned three-way valves.

[0008] As a further optimization of the present invention, the crew cabin module includes a four-way valve, a first heat exchanger, and a second heat exchanger. The four ports of the four-way valve are respectively connected to: the B outlet of a fourth three-way valve, the A outlet of a fifth three-way valve, the inlet of the first heat exchanger, and the outlet of the second heat exchanger. A sixth three-way valve is provided at the outlet of the first heat exchanger. The A outlet of the sixth three-way valve is connected to the A outlet of the fifth three-way valve, and the B outlet of the sixth three-way valve is connected to the B outlet of the fifth three-way valve. The inlet of the second heat exchanger is connected to the A outlet of the second three-way valve. A second one-way valve is provided at the B outlet of the fourth three-way valve. The outlet of the second one-way valve is connected to the A outlet of the second three-way valve. The crew cabin module is used for heat exchange in the crew cabin. By setting two first heat exchangers and a second heat exchanger, the heat exchange effect can be improved, and it is more conducive to dehumidification.

[0009] As a further optimization of the present invention, the battery module includes a third medium pump, a first one-way valve, and a battery cooling channel according to the medium flow direction. The inlet of the battery cooling channel is connected to the B outlet of the third three-way valve, the A outlet of the first three-way valve, and the B outlet of the seventh three-way valve. The outlet of the battery cooling channel is connected to an eighth three-way valve. The A outlet of the eighth three-way valve is connected to the B outlet of the sixth three-way valve, and the B outlet of the eighth three-way valve is connected to the A outlet of the sixth three-way valve. Through the above connection relationship, the battery module can apply waste heat to the passenger compartment, and can also heat or cool the battery.

[0010] As a further optimization of the present invention, an electric heating module is provided at the outlet end of the second flow channel of the first liquid heat exchanger for auxiliary heating under extreme weather conditions.

[0011] As a further optimization of the present invention, the external hot water tank is located inside the car's air intake grille, and the external hot water tank is equipped with an adjustment grille for adjusting the air intake volume of the external hot water tank.

[0012] As a further optimization of the present invention, a first four-way proportional valve is used instead of the first three-way valve and the second three-way valve. The inlet of the first four-way proportional valve is equivalent to the inlet end of the first three-way valve, and the three outlets of the first four-way proportional valve are equivalent to: outlet A of the first three-way valve, outlet A of the second three-way valve, and outlet B of the second three-way valve, respectively.

[0013] The second four-way proportional valve is used instead of the third and fourth three-way valves;

[0014] This solution uses a third four-way proportional valve to replace the fifth and sixth three-way valves, simplifying the valve complexity and improving integration.

[0015] As a further optimization of the present invention, an eight-way valve is used instead of a four-way valve, a third four-way proportional valve, and an eighth three-way valve. This solution is used to further simplify the complexity of the valves. By integrating the pipeline system on the board through each integrated valve, it is beneficial to save space in the layout of new energy vehicles.

[0016] The beneficial effects of this invention are as follows:

[0017] This invention utilizes R290 as the refrigerant, ensuring it is used exclusively in the air conditioning module, thus reducing its dosage. The refrigerant is also centrally distributed for easy protection. Heat is released through a first liquid heat exchanger and absorbed through a second liquid heat exchanger. Furthermore, the passenger compartment module, external heat exchange module, and battery module are combined to create a dual-medium thermal management system. This allows for the introduction of the more thermally efficient R290 refrigerant into the vehicle's thermal management system. Additionally, the optimized pipes and valves can be integrated into a single valve module, helping to reduce space requirements. Attached Figure Description

[0018] Figure 1 This is a system schematic diagram of the present invention;

[0019] Figure 2 This is a schematic diagram of the refrigeration operation of the passenger compartment in this invention;

[0020] Figure 3 This is a schematic diagram of the dual-cooling operation of the passenger compartment and battery in this invention;

[0021] Figure 4 This is a schematic diagram of the motor battery heat dissipation operation of the present invention;

[0022] Figure 5 This is a schematic diagram of the crew cabin heating operation of the present invention;

[0023] Figure 6 This is a schematic diagram of the dual heating mode of the passenger compartment and battery of the present invention;

[0024] Figure 7This is a schematic diagram of the crew cabin heating and motor battery waste heat recovery operation of the present invention;

[0025] Figure 8 This is a schematic diagram of the battery cooling condition during supercharging according to the present invention;

[0026] Figure 9 This is a schematic diagram of the battery air conditioning cooling mode during supercharging of the present invention;

[0027] Figure 10 This is a schematic diagram of the high-temperature environment dehumidification working condition in this invention;

[0028] Figure 11 This is a schematic diagram of the low-temperature dehumidification operation of the present invention;

[0029] Figure 12 This is a schematic diagram of the valve after one-time integration according to the present invention;

[0030] Figure 13 This is a schematic diagram of the valve after secondary integration according to the present invention;

[0031] Figure 14 These are schematic diagrams of the first four-way proportional valve and the second four-way proportional valve of the present invention;

[0032] Figure 15 This is a schematic diagram of the third four-way proportional valve of the present invention;

[0033] In the diagram: ① to ⑧ refer to the first to eighth three-way valves;

[0034] Liquid heat exchangers 1 and 2 refer to the first liquid heat exchanger and the second liquid heat exchanger, respectively.

[0035] Pumps 1, 2, and 3 refer to the first medium pump, the second medium pump, and the third medium pump, respectively.

[0036] Check valves 1 and 2 refer to the first check valve and the second check valve, respectively.

[0037] EXV refers to electronic expansion valve;

[0038] PTC refers to the electric heating module;

[0039] A, B, and C refer to the first four-way proportional valve, the second four-way proportional valve, and the third four-way proportional valve, respectively.

[0040] D refers to an eight-way valve;

[0041] HPT stands for High Pressure Temperature Sensor.

[0042] LPT stands for Low Pressure Temperature Sensor. Detailed Implementation

[0043] The present application will now be described in further detail with reference to the accompanying drawings. It should be noted that the following specific embodiments are only used to further illustrate the present application and should not be construed as limiting the scope of protection of the present application. Those skilled in the art can make some non-essential improvements and adjustments to the present application based on the above application content.

[0044] It should be noted that the three-way valve has one inlet and two outlets. The description of outlet A and outlet B of the three-way valve is only used to distinguish between the two outlets and has no practical significance. It should not be construed as a limitation on the scope of protection of this application.

[0045] Example 1

[0046] like Figure 1-15 As shown, a new energy vehicle thermal management system based on R290 refrigerant is characterized by: including an air conditioning module using R290 refrigerant as the medium, and also including a passenger compartment module, an external heat exchange module, and a battery module. The air conditioning module includes, in sequence according to the flow direction of the medium circuit: a compressor, a first flow channel of a first liquid heat exchanger, a liquid storage drying bottle, an electronic expansion valve, and a first flow channel of a second liquid heat exchanger. The compressor is provided with a high-pressure temperature sensor and a low-pressure temperature sensor at its two ends, respectively.

[0047] The second flow channel of the first liquid heat exchanger is used to heat the passenger compartment module or battery module, or to dissipate heat to the external environment through the external heat exchange module. The second flow channel of the second liquid heat exchanger is used to cool the passenger compartment module or battery module, or to absorb heat from the external environment through the external heat exchange module. It should be noted that, except for the air conditioning module which uses R290 refrigerant, all other circuits in this invention use ordinary liquid media, such as antifreeze water.

[0048] When the second flow channel of the first liquid heat exchanger is used to dissipate heat to the external environment, its circuit sequentially includes the outlet of the first three-way valve B, the outlet of the second three-way valve B, the expansion tank, the external hot water tank, the outlet of the seventh three-way valve A, the cooling flow channel of the motor, the outlet of the fifth three-way valve A, and the first medium pump. When the second flow channel of the second liquid heat exchanger is used to absorb heat to the external environment, its circuit sequentially includes the outlet of the third three-way valve A, the outlet of the fourth three-way valve A, the expansion tank, the external hot water tank, the outlet of the seventh three-way valve A, the cooling flow channel of the motor, the outlet of the fifth three-way valve B, and the second medium pump.

[0049] The crew compartment module includes a four-way valve, a first heat exchanger, and a second heat exchanger. The four ports of the four-way valve are respectively connected to: the B outlet of a fourth three-way valve, the A outlet of a fifth three-way valve, the inlet of the first heat exchanger, and the outlet of the second heat exchanger. A sixth three-way valve is installed at the outlet of the first heat exchanger. The A outlet of the sixth three-way valve is connected to the A outlet of the fifth three-way valve, and the B outlet of the sixth three-way valve is connected to the B outlet of the fifth three-way valve. The inlet of the second heat exchanger is connected to the A outlet of the second three-way valve. A second check valve is installed at the B outlet of the fourth three-way valve, and the outlet of the second check valve is connected to the A outlet of the second three-way valve.

[0050] The battery module includes a third medium pump, a first one-way valve, and a battery cooling channel according to the medium flow direction. The inlet of the battery cooling channel is connected to the B outlet of the third three-way valve, the A outlet of the first three-way valve, and the B outlet of the seventh three-way valve. The outlet of the battery cooling channel is connected to an eighth three-way valve. The A outlet of the eighth three-way valve is connected to the B outlet of the sixth three-way valve, and the B outlet of the eighth three-way valve is connected to the A outlet of the sixth three-way valve.

[0051] An electric heating module is installed at the outlet end of the second flow channel of the first liquid heat exchanger to assist in heating under extreme weather conditions.

[0052] The external hot water tank is located inside the car's air intake grille and is equipped with an adjustable grille to regulate the air intake volume of the external hot water tank.

[0053] The first four-way proportional valve is used to replace the first three-way valve and the second three-way valve. The inlet of the first four-way proportional valve is equivalent to the inlet end of the first three-way valve, and the three outlets of the first four-way proportional valve are equivalent to: outlet A of the first three-way valve, outlet A of the second three-way valve, and outlet B of the second three-way valve, respectively.

[0054] The second four-way proportional valve is used instead of the third and fourth three-way valves;

[0055] The third four-way proportional valve is used instead of the fifth three-way valve and the sixth three-way valve.

[0056] An eight-way valve is used instead of a four-way valve, a third four-way proportional valve, and an eighth three-way valve.

[0057] The specific implementation method is as follows:

[0058] Operating Condition 1: Figure 2 As shown, the crew compartment is refrigerated. At this time, the outlet of the first three-way valve B is open, the outlet of the second three-way valve B is open, the outlet of the third three-way valve A is open, the outlet of the fourth three-way valve B is open, the outlet of the fifth three-way valve A is open, and the outlet of the sixth three-way valve B is open. The first liquid heat exchanger dissipates heat to the air through the external hot water tank and refrigerates the crew compartment through the second liquid heat exchanger.

[0059] Operating Condition 2: (e.g.) Figure 3As shown, the crew compartment and battery are dual-cooled. Unlike the first operating condition, the outlet of the third three-way valve B is open and the outlet of the eighth three-way valve A is open, so that the refrigerant flows through the crew compartment module and the battery module.

[0060] Operating Condition 3: (e.g.) Figure 4 As shown, the motor and battery are cooled. This working condition is used for conventional motor and battery cooling. This cooling effect is often used in weather with moderate temperature. The cooling needs of the motor and battery can be met by simply replacing the heat in the external hot water tank.

[0061] Operating Condition 4: (e.g.) Figure 5 As shown, in the crew compartment heating mode, the second channel of the second liquid heat exchanger is connected to the external heat exchange module to absorb heat from the external environment, and the second channel of the first liquid heat exchanger is connected to the crew compartment to heat the crew compartment.

[0062] Operating Condition 5: (e.g.) Figure 6 As shown, the crew compartment and battery are heated simultaneously. Unlike the fourth condition, the outlet of the first three-way valve A is open and the outlet of the eighth three-way valve B is open, so that the medium in the second channel of the first liquid heat exchanger flows to the crew compartment module and the battery module respectively.

[0063] Operating Condition 6: (e.g.) Figure 7 As shown, the crew compartment is heated and the motor and battery waste heat is recovered. Under this condition, the second channel of the first liquid heat exchanger is connected to the crew compartment module, and the second channel of the second liquid heat exchanger absorbs heat from the external hot water tank, as well as the motor and battery.

[0064] Operating Condition 7: (e.g.) Figure 8 As shown, the battery cools down during supercharging, and during fast charging, it is cooled down by an external hot water tank to prevent the battery temperature from getting too high.

[0065] Operating Condition 8: (e.g.) Figure 9 As shown, the battery air conditioning cooling during supercharging differs from that in operating condition seven. When the ambient temperature is high, it is difficult to achieve cooling by relying solely on the external hot water tank. Therefore, the air conditioning module is involved, using the first liquid heat exchanger to release heat to the external environment and the second liquid heat exchanger to cool the battery.

[0066] Operating Condition 9: (e.g.) Figure 10 As shown, in medium- and high-temperature environments, dehumidification is achieved by switching the connection relationship through a four-way valve, which connects the first heat exchanger with the second channel of the second liquid heat exchanger for cooling and simultaneously condenses moisture. The second channel of the first liquid heat exchanger is connected to the second heat exchanger in the passenger compartment and the external heat exchange module for heat release. This heat release is used to cool the external environment. If the environment is medium-temperature and cooling is not required, the second heat exchanger is used to release the heat absorbed by the first heat exchanger back to the passenger compartment. If the environment is high-temperature, the outlet of the second three-way valve A is closed, the second heat exchanger is in the disconnected state, and heat is only released to the external environment.

[0067] Operating Condition 10: (e.g.) Figure 11 As shown, dehumidification in low-temperature environments needs to balance dehumidification and heating. The external heat exchange module and the first heat exchanger are connected in parallel to the second channel of the second liquid heat exchanger for heat absorption. The first heat exchanger absorbs heat in the crew compartment to condense moisture, while the second heat exchanger is connected to the second channel of the first liquid heat exchanger to return the heat to the crew compartment for heating.

[0068] Figure 14 as well as Figure 15 An implementation of the first four-way proportional valve, the second four-way proportional valve, and the third four-way proportional valve is given. Both the four-way proportional valve and the eight-way valve are existing technologies. In operating condition 9, the four-way proportional valve can be used to adjust the flow ratio, so that the heat medium flowing into the second heat exchanger and the external hot water tank can be adjusted according to the temperature requirements, so that some heat can be recovered to the crew compartment through the second heat exchanger as needed.

[0069] The embodiments described above are merely examples of several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention.

Claims

1. A thermal management system for new energy vehicles based on R290 refrigerant, characterized in that: The system includes an air conditioning module that uses R290 refrigerant as the medium, as well as a passenger compartment module, an external heat exchange module, and a battery module. The air conditioning module includes, in sequence according to the flow direction of the medium circuit, a compressor, a first flow channel of a first liquid heat exchanger, a liquid receiver drying bottle, an electronic expansion valve, and a first flow channel of a second liquid heat exchanger. The second flow channel of the first liquid heat exchanger is used to heat the crew cabin module or battery module, or to dissipate heat to the external environment through the external heat exchange module; the second flow channel of the second liquid heat exchanger is used to cool the crew cabin module or battery module, or to absorb heat from the external environment through the external heat exchange module. When the second flow channel of the first liquid heat exchanger is used to dissipate heat to the external environment, its circuit sequentially includes the outlet of the first three-way valve B, the outlet of the second three-way valve B, the expansion tank, the external hot water tank, the outlet of the seventh three-way valve A, the cooling flow channel of the motor, the outlet of the fifth three-way valve A, and the first medium pump. When the second flow channel of the second liquid heat exchanger is used to absorb heat to the external environment, its circuit sequentially includes the outlet of the third three-way valve A, the outlet of the fourth three-way valve A, the expansion tank, the external hot water tank, the outlet of the seventh three-way valve A, the cooling flow channel of the motor, the outlet of the fifth three-way valve B, and the second medium pump. The crew compartment module includes a four-way valve, a first heat exchanger, and a second heat exchanger. The four ports of the four-way valve are respectively connected to: the B outlet of a fourth three-way valve, the A outlet of a fifth three-way valve, the inlet of the first heat exchanger, and the outlet of the second heat exchanger. A sixth three-way valve is provided at the outlet of the first heat exchanger. The A outlet of the sixth three-way valve is connected to the A outlet of the fifth three-way valve, and the B outlet of the sixth three-way valve is connected to the B outlet of the fifth three-way valve. The inlet of the second heat exchanger is connected to the A outlet of the second three-way valve. A second check valve is provided at the B outlet of the fourth three-way valve, and the outlet of the second check valve is connected to the A outlet of the second three-way valve.

2. The new energy vehicle thermal management system based on R290 refrigerant according to claim 1, characterized in that: The battery module includes a third medium pump, a first one-way valve, and a battery cooling channel according to the medium flow direction. The inlet of the battery cooling channel is connected to the B outlet of the third three-way valve, the A outlet of the first three-way valve, and the B outlet of the seventh three-way valve. The outlet of the battery cooling channel is connected to an eighth three-way valve. The A outlet of the eighth three-way valve is connected to the B outlet of the sixth three-way valve, and the B outlet of the eighth three-way valve is connected to the A outlet of the sixth three-way valve. 3.The R290-based new energy vehicle thermal management system according to claim 1, characterized in that: An electric heating module is provided at the outlet end of the second flow channel of the first liquid heat exchanger to assist in heating under extreme weather conditions.

4. The new energy vehicle thermal management system based on R290 refrigerant of claim 1, wherein: The external hot water tank is located inside the car's air intake grille, and the external hot water tank is equipped with an adjustable grille for adjusting the air intake volume of the external hot water tank.

5. A new energy vehicle thermal management system based on R290 refrigerant according to claim 2, characterized in that: The first four-way proportional valve is used to replace the first three-way valve and the second three-way valve. The inlet of the first four-way proportional valve is equivalent to the inlet end of the first three-way valve, and the three outlets of the first four-way proportional valve are equivalent to: outlet A of the first three-way valve, outlet A of the second three-way valve, and outlet B of the second three-way valve, respectively. The second four-way proportional valve is used instead of the third and fourth three-way valves; The third four-way proportional valve is used instead of the fifth three-way valve and the sixth three-way valve.

6. A new energy vehicle thermal management system based on R290 refrigerant according to claim 5, characterized in that: An eight-way valve is used instead of a four-way valve, a third four-way proportional valve, and an eighth three-way valve.

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