An integrated heat pump liquid storage drying valve island system

Abstract

This invention relates to the field of new energy thermal management systems, and more particularly to an integrated heat pump liquid storage and drying valve island system. The system includes an integrated valve island system, and a compressor, an air conditioning heating system, an external heat exchanger, an air conditioning evaporator, and a battery cooling evaporator, all connected to the integrated valve island system. High-pressure, vulnerable components of the heat pump system are individually integrated, facilitating system assembly while reducing maintenance and replacement costs. An architecture for the high-pressure section of the refrigerant in the heat pump system is designed for the integration of specific components, improving installation efficiency. A high-pressure side integrated architecture compatible with both direct and indirect heat pump systems is designed, with the high-pressure, high-temperature side arranged independently to eliminate the thermal interference of large integration on the low-pressure, low-temperature refrigerant. The integration of high-pressure, vulnerable components allows for easy disassembly of each component, reducing the overall system maintenance and replacement costs. This invention solves the technical problems of difficult repairs and high maintenance costs in existing thermal management systems after a failure.

Description

Technical Field

[0001] This invention relates to the field of new energy thermal management systems, and more particularly to an integrated heat pump liquid storage and drying valve island system. Background Technology

[0002] The thermal management system in new energy vehicles encompasses thermal management and control of four parts: the driver and passenger compartment, vehicle electronic control, vehicle electric drive, and vehicle battery. In the heat pump system of new energy vehicles, various valves and system components are typically installed independently, leading to high installation complexity, inconvenient maintenance, and significant space occupation. Especially in heat pump systems, numerous thermal management components are required. Integrated development of the entire vehicle's thermal management system is a development trend in the industry. Integrated development effectively reduces connecting pipes and brackets, significantly lowering the complexity and cost of system connections. Therefore, a heat pump integrated valve island system that can integrate multiple functions is needed to improve system reliability and efficiency while simplifying installation and maintenance.

[0003] However, even highly integrated valve islands in a system can present challenges in repair after a failure. The damage to a single component can necessitate the replacement of the entire system, as detailed below:

[0004] 1) Heat pump-type automotive thermal management systems are complex to install;

[0005] 2) Internal thermal interference in the integrated thermal management module leads to low efficiency of the automotive thermal management system;

[0006] 3) Complex automotive thermal management systems are difficult to maintain;

[0007] 4) Highly integrated thermal management components have high maintenance costs.

[0008] In integrated automotive thermal management systems, the integration of high and low pressure systems can cause additional heat loss due to the thermal effects of high and low temperatures. Therefore, it is recommended to separate the high and low pressure systems to eliminate the impact of heat load on internal heat exchange. In existing automotive thermal management systems, the integrated components are mainly located on the low-pressure side. However, the reliability, leakage, and functional failure risks of automotive thermal management systems are primarily concentrated on the high-pressure side. Damage to high-pressure side components can easily lead to the replacement of multiple components, or even the entire low-pressure side integrated module, resulting in high maintenance costs. Therefore, existing thermal management systems suffer from difficulties in repairing after a failure and high maintenance costs. Summary of the Invention

[0009] The purpose of this invention is to provide an integrated heat pump liquid storage and drying valve island system that can solve the technical problems of difficult maintenance and high maintenance costs after the failure of the existing thermal management system.

[0010] To achieve the above objectives, the present invention provides an integrated heat pump liquid storage and drying valve island system, comprising an integrated valve island system, a compressor, an air conditioning heating system, an external heat exchanger, an air conditioning evaporator, and a battery-cooled evaporator, all connected to the integrated valve island system. The air conditioning evaporator is connected to the integrated valve island system via a first electronic expansion valve, and the battery-cooled evaporator is connected to the integrated valve island system via a second electronic expansion valve. The other ends of the air conditioning evaporator and the battery-cooled evaporator are respectively connected to the inlet end of the compressor. The integrated valve island system is used to switch between cooling and heating modes of the integrated heat pump liquid storage and drying valve island system.

[0011] As a preferred embodiment, the integrated valve island system includes a liquid storage and drying tank located on the high-pressure side of the heat pump system, a valve island body, a refrigerant three-way valve, a refrigerant electronic expansion valve, and a refrigerant one-way valve. The liquid storage and drying tank and the valve island body are provided with refrigerant flow holes, and the refrigerant three-way valve, the refrigerant electronic expansion valve, and the refrigerant one-way valve are respectively connected to the interface on the valve island body.

[0012] Furthermore, the interfaces on the valve island body include a one-way valve interface, an external heat exchanger interface, a compressor interface, and an evaporator interface. The one-way valve interface is connected to the refrigerant electronic expansion valve and the external heat exchanger, respectively. The external heat exchanger interface is connected to the refrigerant three-way valve and the external heat exchanger, respectively. The compressor interface is connected to the refrigerant three-way valve, and the evaporator interface is connected to the air conditioner evaporator and the battery-cooled evaporator, respectively.

[0013] As a preferred embodiment, when the integrated heat pump storage and drying valve island system enters the passenger compartment air source heat pump heating mode, the refrigerant after heat exchange from the compressed refrigerant enters the refrigerant three-way valve from the compressor interface. This valve is open to the left and right but closed to the lower right. The refrigerant flows through the storage and drying tank, expands through the refrigerant electronic expansion valve, and then enters the external heat exchanger through the one-way valve interface. At this time, the refrigerant absorbs the waste heat of the air to heat the passenger compartment and realize the air source heat pump heating function.

[0014] As a preferred embodiment, when the integrated heat pump storage and drying valve island system enters the crew cabin water source heat pump heating mode, the refrigerant after heat exchange from the compressed refrigerant enters the refrigerant three-way valve from the compressor interface. This valve is open to the left and right but closed to the lower right. The refrigerant flows out of the evaporator interface through the storage and drying tank. At this time, the refrigerant electronic expansion valve is closed, and the outflowing refrigerant expands through the second electronic expansion valve and passes through the battery-cooled evaporator to absorb heat from the battery or electric drive coolant water source and return to the compressor to realize the crew cabin water source heat pump heating function.

[0015] As a preferred embodiment, when the integrated heat pump liquid storage and drying valve island system enters the passenger compartment cooling mode, the compressed refrigerant enters the refrigerant three-way valve from the compressor interface. This valve is closed to the left and right but open to the lower right. The refrigerant flows out through the external heat exchanger interface to the external heat exchanger for external heat exchange and condensation. The liquid refrigerant returns to the integrated liquid storage and drying valve island system through the one-way valve interface and is stored in the liquid storage and drying tank. At this time, the refrigerant electronic expansion valve is closed, and the liquid refrigerant flows out from the evaporator interface to the outside, expands through the first electronic expansion valve, and flows into the air conditioning evaporator to absorb heat from the passenger compartment air, thereby achieving passenger compartment cooling.

[0016] As a preferred embodiment, the air conditioning heating system is an air conditioning heater used in a direct heat pump system, and the air conditioning heater is connected to the compressor outlet and the integrated valve island system respectively.

[0017] As a preferred embodiment, the air conditioning heating system comprises a water-cooled condenser and an air conditioning heater heat exchanger, used in an indirect heat pump system. The water-cooled condenser is connected to the compressor outlet and the integrated valve island system, respectively, and the air conditioning heater heat exchanger is connected to the water-cooled condenser.

[0018] The beneficial effects of this invention are:

[0019] This invention provides an integrated heat pump liquid storage and drying valve island system, which separately integrates the high-pressure vulnerable components of the heat pump system, facilitating system assembly while reducing maintenance and replacement costs.

[0020] 1) Design an architecture for the high-pressure refrigerant section of a heat pump system to integrate specific components and improve installation efficiency.

[0021] 2) Design a high-pressure side integrated architecture compatible with both direct and indirect heat pump systems, and arrange the high-pressure and high-temperature side independently to eliminate the thermal interference of large integration on the low-pressure and low-temperature refrigerant.

[0022] 3) Design a three-dimensional spatial structure for the physical valve island structure of the integrated system to maximize space utilization.

[0023] 4) The high-voltage vulnerable components of the system are integrated, and each component can be easily disassembled, reducing the overall system maintenance and replacement costs.

[0024] This invention can solve the technical problems of difficult repair and high maintenance costs after the failure of the existing thermal management system. Attached Figure Description

[0025] Figure 1 This is a diagram of the direct heat pump system architecture of the present invention.

[0026] Figure 2 This is a diagram of the indirect heat pump system architecture of the present invention.

[0027] Figure 3 This is a diagram of the integrated valve island system of the present invention.

[0028] Figure 4 This is a diagram of the integrated valve island assembly of the present invention.

[0029] Figure 5 This is a perspective view of one side of the valve island body of the present invention.

[0030] Figure 6 This is a perspective view of the other side of the valve island body of the present invention.

[0031] Explanation of reference numerals in the attached figures:

[0032] 1.1 Compressor, 1.2 Air Conditioner Heater, 1.3 Integrated Valve Island System, 1.4 External Heat Exchanger, 1.5 Two-way Valve, 1.6 First Electronic Expansion Valve, 1.7 Air Conditioner Evaporator, 1.8 Second Electronic Expansion Valve, 1.9 Battery-cooled Evaporator, 2.1 Water-cooled Condenser, 2.2 Air Conditioner Heating Heat Exchanger; 1.3 Integrated Valve Island System: 3.1 Refrigerant Three-way Valve, 3.2 Liquid Receiver Dryer, 3.3 Refrigerant Electronic Expansion Valve, 3.4 Refrigerant Check Valve, 3.5 Valve Island Body;

[0033] One-way valve interface a, external heat exchanger interface b, compressor interface c, evaporator interface d, refrigerant electronic expansion valve interface e, refrigerant three-way valve interface f, liquid receiver dryer inlet g, liquid receiver dryer outlet h. Detailed Implementation

[0034] To make the technical problems solved by this invention, the technical solutions adopted, and the technical effects achieved clearer, the technical solutions of this invention will be further described below in conjunction with the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are only for explaining this invention and not for limiting it. Furthermore, it should be noted that, for ease of description, only the parts related to this invention are shown in the accompanying drawings, not all of them.

[0035] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to fixed connections or detachable connections; mechanical connections or electrical connections; direct connections or indirect connections through an intermediate medium; and internal connections between two components. Those skilled in the art can understand the specific meaning of these terms in this invention based on the specific circumstances.

[0036] Since the reliability leaks and functional failures of automotive thermal management systems primarily occur on the high-pressure side, and high maintenance costs arise from the need to replace all highly integrated modules due to high-pressure damage to the integrated modules, this invention provides an architecture compatible with heat pump systems. Based on this architecture, a valve island solution for the integrated arrangement of the high-pressure side of the system is also provided to improve system integration and reduce the difficulty and cost of system installation and maintenance. This invention spatially integrates the high-pressure side thermal management components of the system, facilitating vehicle installation and maintenance.

[0037] This invention relates to batteries, electric drives, passenger compartment thermal management systems, and integrated valve island components for new energy vehicles. In particular, it relates to an integrated heat pump liquid storage and drying valve island system, including switching between air source heat pump mode, water source heat pump mode, and cooling mode, compatible with both direct and indirect heat pump systems.

[0038] In response to the problems mentioned in the background art, this invention addresses the issue of separately integrating high-pressure vulnerable components of heat pump systems, thereby facilitating system assembly while reducing maintenance and replacement costs.

[0039] To solve the above problems, the focus of this invention is:

[0040] 1) Design an architecture for the high-pressure refrigerant section of a heat pump system to integrate specific components and improve installation efficiency.

[0041] 2) Design a high-pressure side integrated architecture compatible with both direct and indirect heat pump systems, and arrange the high-pressure and high-temperature side independently to eliminate the thermal interference of large integration on the low-pressure and low-temperature refrigerant.

[0042] 3) Design a three-dimensional spatial structure for the physical valve island structure of the integrated system to maximize space utilization.

[0043] 4) The high-voltage vulnerable components of the system are integrated, and each component can be easily disassembled, reducing the overall system maintenance and replacement costs.

[0044] This invention, an integrated heat pump refrigerant storage and drying valve island system, designs a heat pump system architecture that physically integrates the refrigerant valve on the high-pressure side of the heat pump system with the refrigerant storage and drying tank. The integrated component is mainly located on the high-pressure side of the system's refrigerant, controlling the refrigerant flow for both heat pump heating and air conditioning cooling modes. The integrated connection of related components reduces the number of pipes and supports, thereby reducing costs.

[0045] This invention includes an integrated heat pump liquid receiver drying architecture and corresponding component valve island products. The integrated heat pump liquid receiver drying valve island includes: a liquid receiver drying tank, a filter, a desiccant, a sealing ring, a refrigerant three-way valve, a refrigerant one-way valve, a refrigerant electronic expansion valve, an integrated valve island, and bolts. The integrated valve island body serves as a supporting connection. The refrigerant three-way valve and the refrigerant electronic expansion valve are fixed to the valve island body with bolts. The liquid receiver drying tank is welded to the integrated valve island. A refrigerant one-way valve is press-fitted inside the central integrated valve island. This integrated valve island system can switch between the air source or the coolant source to recover heat for the driver's compartment during winter heating, depending on different vehicle operating conditions. It can also switch the system's cooling mode to transfer heat from the passenger compartment to the air side during summer when the passenger compartment needs cooling, thus achieving switching between cooling and heating modes. Furthermore, this invention physically integrates the high-pressure side of the system, improving the system's local integration and facilitating vehicle installation and maintenance. The system architecture pattern is clearly described, the overall architecture loop function mode switching principle is correct, and the physical structure integration is clearly described. Therefore, this invention has a high degree of feasibility and maturity and can be mass-produced in new energy vehicles.

[0046] This invention provides an integrated heat pump liquid storage and drying valve island system, comprising an integrated valve island system, a compressor, an air conditioning heating system, an external heat exchanger, an air conditioning evaporator, and a battery-cooled evaporator, all connected to the integrated valve island system. The air conditioning evaporator is connected to the integrated valve island system via a first electronic expansion valve, and the battery-cooled evaporator is connected to the integrated valve island system via a second electronic expansion valve. The other ends of the air conditioning evaporator and the battery-cooled evaporator are respectively connected to the inlet end of the compressor. The integrated valve island system is used to switch between cooling and heating modes of the integrated heat pump liquid storage and drying valve island system.

[0047] 1. Architecture of a heat pump system:

[0048] Currently, the thermal management systems of new energy vehicles primarily operate independently for each component. The battery system's heat pipes and the passenger compartment's thermal management system function as separate system loops. This independent operation of components across different system modules fails to centrally distribute heat across the entire vehicle. Particularly in passenger compartment heating mode, the lack of a heat pump system for low-power heating results in significant energy loss during thermal management, reducing battery range. Therefore, to address this issue, this invention proposes a multi-mode functional heat pump system architecture that integrates the passenger compartment, battery pack, and electronic control system. This architecture includes passenger compartment cooling / heating modes and battery cooling / heating modes to meet the thermal management requirements of various driving conditions. This improves the overall vehicle range, especially during winter when passenger compartment heating is required.

[0049] The system architecture of this invention mainly includes a refrigerant circuit, which is divided into a direct heat pump system architecture and an indirect heat pump system architecture.

[0050] In the architecture of a direct heat pump system, combined with Figure 1 As shown, the refrigerant circuit includes an electric compressor 1.1 that compresses the refrigerant. After compression, the high-temperature and high-pressure refrigerant undergoes heat exchange through an air conditioning heater 1.2. At this time, the high-temperature refrigerant exchanges heat with the low-temperature air through the air conditioning heater and is then introduced into the passenger compartment to heat the passenger compartment. After heat exchange, the refrigerant passes through an integrated heat pump liquid storage and drying valve island system 1.3 and, depending on different mode requirements, enters an external heat exchanger 1.4 and a refrigerant two-way valve 1.5 before returning to the compressor 1.1 for the next cycle. The refrigerant can also enter the air conditioning evaporator 1.7 from the integrated heat pump liquid storage and drying valve island system 13 through the first electronic expansion valve 1.6 to achieve the cab cooling function; or it can pass through the second electronic expansion valve 1.8 and flow through the expansion flow to the battery cooling evaporator 1.9 to achieve the cooling of the battery coolant.

[0051] In the architecture of an indirect heat pump system, combined with Figure 2 As shown, the refrigerant circuit includes an electric compressor 1.1 that compresses the refrigerant. After compression, the high-temperature, high-pressure refrigerant undergoes heat exchange in a water-cooled condenser 2.1. At this time, the high-temperature refrigerant exchanges heat with the low-temperature coolant through the water-cooled condenser 2.1. The heated coolant exchanges heat with the air through the air conditioning heater heat exchanger 2.2 and is then introduced into the passenger compartment for heating. After heat exchange, the refrigerant passes through the integrated heat pump liquid storage and drying valve island system 1.3 and, depending on different mode requirements, enters the external heat exchanger 1.4 and the refrigerant two-way valve 1.5 before returning to the compressor 1.1 for the next cycle. Alternatively, the refrigerant can enter the air conditioning evaporator 1.7 from the integrated heat pump liquid storage and drying valve island system 1.3 through the first electronic expansion valve 1.6 to achieve the cab cooling function; or it can pass through the second electronic expansion valve 1.8 and flow into the battery cooling evaporator 1.9 to cool the battery coolant.

[0052] 2. Integrated heat pump liquid storage and drying valve island system:

[0053] In the proposed heat pump system architecture, the liquid storage and drying tank and various refrigerant valves in the refrigerant distribution circuit on the high-pressure side of the heat pump system are further integrated into an independent refrigerant storage and distribution system. This system stores high-temperature and high-pressure refrigerant and isolates it from the temperature of other circuits to eliminate thermal effects. At the same time, this integrated system can switch between different vehicle driving conditions, such as passenger compartment cooling mode, passenger compartment heat pump heating mode, and battery cooling mode, to ensure that the system functions meet the needs of the vehicle.

[0054] Combination Figure 3As shown, the integrated heat pump liquid storage and drying valve island system 1.3 of the present invention mainly includes four external connection ports: a, b, c, and d. The refrigerant at port c first enters port b or flows to the liquid storage and drying tank 3.2 via a refrigerant three-way valve 3.1. At this point, due to the action of the one-way valve 3.4, the refrigerant cannot flow to the left. After passing through the liquid storage and drying tank 3.2, it flows out of port b according to the mode requirement, or flows out of port a via a refrigerant electronic expansion valve. This constitutes the integrated heat pump liquid storage and drying valve island system of the present invention.

[0055] 3. Structural design of the integrated valve island:

[0056] In the proposed integrated heat pump liquid storage and drying valve island system, the liquid storage and drying tank, filter, desiccant, sealing ring, refrigerant three-way valve, refrigerant one-way valve, refrigerant electronic expansion valve, integrated valve island, bolts, and other components of the refrigerant distribution system are integrated into a single design. In the core integrated valve island design, this invention proposes a structure different from the current two-dimensional integrated flow channel plates, employing a three-dimensional spatial integrated valve island to integrate the various components. This significantly improves the space utilization rate of the integrated system, reduces the overall space occupation of the integrated valve island, and reduces the piping and support structures connecting various thermal management components. This structure is convenient for installation, maintenance, and replacement, has a compact design, and high system operating efficiency.

[0057] Combined with appendix Figure 3 The integrated heat pump liquid storage and drying valve island system, the corresponding integrated components are shown in [link to integrated components]. Figure 4-6 This structure integrates a valve island as its core, connecting various thermal management components. The high-pressure side core components—the liquid storage and drying tank, electronic expansion valve, refrigerant three-way valve, and refrigerant check valve—are mounted on this valve island. Different ports within the valve island connect to the various thermal management components, forming system channels. This allows for switching the refrigerant flow in different thermal management modes, enabling vehicle thermal management for passenger compartment heating and cooling, as well as battery cooling. The valve island structure is a three-dimensional space structure. The four valve island connection ports a, b, c, and d are externally connected, while two internal spatial holes connect to each other. This structure achieves spatial integration of thermal management components and mutual flow of refrigerant channels, enabling switching between different modes.

[0058] The following is combined Figures 4 to 6 The technical solution of the present invention will be further explained.

[0059] The present invention relates to an integrated heat pump liquid storage and drying valve island system, comprising three parts: a heat pump system architecture, a high-pressure side liquid storage and drying integrated valve island system, and an integrated valve island assembly.

[0060] The first part is the heat pump system architecture. The system architecture of this invention includes direct and indirect heat pump refrigerant systems, and the switching of the circuit includes the passenger compartment cooling and heating mode, battery cooling mode, etc.

[0061] Combination Figure 1 In the direct heat pump system shown, the refrigerant circuit includes an electric compressor 1.1 that compresses the refrigerant. The compressed refrigerant then exchanges heat with the low-temperature air in the passenger compartment via an air conditioning heater 1.2. The heated air in the passenger compartment is then blown into the passenger compartment by a blower to provide heating. The refrigerant then passes through an integrated heat pump receiver-drier valve island system 1.3, where mode selection is performed. When there is residual heat in the air, the refrigerant flows to an external heat exchanger 1.4 to absorb the residual heat from the environment and then returns to the compressor via a two-way valve 1.5 for the next cycle. When there is residual heat in the battery or electric drive system, the first electronic expansion valve 1.6 closes, and the refrigerant flows through a second electronic expansion valve 1.8 to the battery cooling evaporator 1.9 to absorb the residual heat from the battery or electric drive system before returning to the compressor for the next cycle. This system achieves a heat pump heating mode that absorbs residual heat from both the air source and the battery / electric drive source.

[0062] When the passenger compartment requires cooling, the compressor 1.1 compresses the refrigerant, which flows through the air conditioning heater 1.2 without heat exchange. The refrigerant then flows to the integrated heat pump liquid receiver-drier valve island system 1.3, where its route is switched. First, it passes through an external heat exchanger to dissipate heat into the environment, causing the refrigerant to condense into a liquid and return to the integrated heat pump liquid receiver-drier valve island system 1.3 for storage. The liquid refrigerant then expands through the first electronic expansion valve 1.6 and flows into the air conditioning evaporator 1.7 to absorb heat from the passenger compartment air, thus cooling the passenger compartment. Finally, the refrigerant returns to the compressor 1.1 for the next cycle. In summary, this direct heat pump system architecture enables multiple passenger compartment heat pump heating and cooling modes.

[0063] Combination Figure 2 In the indirect heat pump system shown, the refrigerant circuit includes an electric compressor 1.1 that compresses the refrigerant. The compressed refrigerant then passes through a water-cooled condenser 2.1 for heat exchange with the coolant in the air conditioning / heating heat exchanger 2.2. The heated coolant then exchanges heat with the passenger cabin air through the air conditioning / heating heat exchanger 2.2. The heated air in the low-temperature passenger cabin is then blown into the passenger cabin by a blower to provide heating. The refrigerant then passes through an integrated heat pump receiver-drier valve island system 1.3, where a mode selection occurs. When there is residual heat in the air, the refrigerant flows to an external heat exchanger 1.4 to absorb the residual heat from the environment and then returns to the compressor through a two-way valve 1.5 for the next cycle. When there is residual heat in the battery or electric drive system, the first electronic expansion valve 1.6 closes, and the refrigerant flows through a second electronic expansion valve 1.8 to the battery cooling evaporator 1.9 to absorb the residual heat from the battery or electric drive system before returning to the compressor for the next cycle. This system achieves a heat pump heating mode that absorbs residual heat from both the air source and the battery / electric drive source.

[0064] When the passenger compartment requires cooling, the compressor 1.1 compresses the refrigerant, which flows through the water-cooled condenser 2.1 without heat exchange. The refrigerant then switches its route to the integrated heat pump liquid receiver-drier valve island system 1.3. First, it passes through an external heat exchanger to dissipate heat into the environment, causing the refrigerant to condense into a liquid and return to the integrated heat pump liquid receiver-drier valve island system 1.3 for storage. The liquid refrigerant then expands through the first electronic expansion valve 1.6 and flows into the air conditioning evaporator 1.7 to absorb heat from the passenger compartment air, thus cooling the passenger compartment. Finally, the refrigerant returns to the compressor 1.1 for the next cycle. In summary, this indirect heat pump system architecture enables multiple passenger compartment heat pump heating and cooling modes.

[0065] The second part is the high-pressure side liquid storage and drying integrated valve island system. The high-pressure side liquid storage and drying integrated valve island system of the present invention integrates the high-pressure side thermal management components of the first invention.

[0066] Combination Figure 3 As shown, it is for Figure 1 Invention details of the integrated valve island system 1.3 for medium and high pressure side liquid storage and drying, including the four inlet / outlet ports a, b, c, and d of the integrated valve island system 1.3 for high pressure side liquid storage and drying. Figure 3 The four exits are defined the same.

[0067] When the system enters the crew cabin air source heat pump heating mode, the refrigerant after heat exchange from the compressed refrigerant... Figure 3 The refrigerant enters through port c in the refrigerant three-way valve 3.1. This valve is open to the left and right, but closed to the lower right. The refrigerant flows through the liquid storage dryer 3.2 and expands through the refrigerant electronic expansion valve 3.3 before entering the external heat exchanger 1.4 through port a. At this time, the refrigerant absorbs the waste heat of the air to heat the crew cabin and realize the air source heat pump heating function.

[0068] When the system activates the crew compartment water source heat pump for heating, the refrigerant after heat exchange from the compressed refrigerant... Figure 3 The refrigerant enters through port c in the refrigerant three-way valve 3.1. This valve is open to the left and right but closed to the lower right. The refrigerant flows out through port d via the liquid storage dryer 3.2. At this time, the refrigerant electronic expansion valve 3.3 is closed. The outflowing refrigerant expands through the second electronic expansion valve 1.8 and passes through the battery cooling evaporator 1.9 to absorb heat from the battery or electric drive coolant water source and return to the compressor to realize the crew cabin water source heat pump heating function.

[0069] When the system enters the crew cabin cooling mode, the compressed refrigerant flows from... Figure 3The refrigerant enters through port c in the refrigerant three-way valve 3.1. This valve is closed to the left and right but open to the lower right. The refrigerant flows out through port b to the external heat exchanger 1.4 for external heat exchange and condensation. The liquid refrigerant returns through port a to the liquid storage and drying integrated valve island system 1.3 and is stored in the liquid storage and drying tank 3.2. At this time, the refrigerant electronic expansion valve is closed, and the liquid refrigerant flows out through port d to the outside, expands through the first electronic expansion valve 1.6, and flows into the air conditioning evaporator 1.7 to absorb heat from the passenger compartment air, thus achieving passenger compartment cooling.

[0070] In summary, this system enables the heating function of the heat pump cabin air source and water source, and can also achieve the cooling function of the cabin.

[0071] The third part, the integrated valve island assembly, provides a detailed structural description of the high-pressure side heat pump liquid storage and drying integrated valve island system, which is part of the invention described in the second part.

[0072] Combination Figure 4 As shown, the integrated valve island assembly includes four external connection interfaces: a, b, c, and d. The valve island body (3.5), as the core of the system, is connected to the liquid storage and drying tank via brazing. (Refer to...) Figure 6 The g and h ports are connected to the inlet and outlet of the liquid storage and drying tank. Refrigerant flows out from the g outlet of the integrated valve island, is stored in the liquid storage and drying tank, and then flows into the valve island body 3.5 from the h inlet. The refrigerant three-way valve 3.1 is bolted to the valve island body 3.5 at port f. The refrigerant electronic expansion valve 3.3 is bolted to the valve island body 3.5 at port e. The one-way valve 3.4 is press-fitted to the valve island body 3.5 at port a. All these thermal management system components are uniformly arranged in the connecting body centered on the integrated valve island to realize the relevant system functions.

[0073] In the air-source heat pump passenger compartment heating mode, the refrigerant after compression and heat exchange... Figure 4 The refrigerant flows into the integrated valve island assembly through port C, and is controlled by the refrigerant three-way valve to open from port C to port G. At this time, the hole 5.1 of the integrated valve island connects the spaces. The refrigerant flows from port G through the liquid storage and drying tank, then through port H back to the valve island body 3.5, and then through hole 5.3 into the refrigerant electronic expansion valve 3.3 at port E of the valve island body 3.5. After expansion, it flows out from port A to the external heat exchanger to absorb heat from the air, and then returns to the compressor for the next cycle, thus realizing the heating function of the air source heat pump in the passenger compartment.

[0074] In battery or electric-powered water-sourced crew cabin heat pump heating mode, the refrigerant after compression heat exchange... Figure 4The refrigerant flows into the integrated valve island assembly through port C. The refrigerant is controlled by the three-way valve to open from port C to port G. At this time, the hole 5.1 of the integrated valve island connects the space. The refrigerant flows from port G to the liquid storage and drying tank and then returns to the valve island body 3.5 through port H. Port H is the same as port D. The liquid refrigerant flows out from port D to the second electronic expansion valve 1.8 and then passes through the battery cooling evaporator 1.9 to absorb the heat of the battery or electric drive coolant, so as to realize the heat pump heating function of the battery and electric drive water source crew compartment.

[0075] In the passenger compartment cooling mode, after compression by the compressor, the refrigerant enters the valve island body 3.5 through port c. The refrigerant three-way valve 3.1 switches the connection between port c and port b. After compression, the refrigerant enters the external heat exchanger 1.4 through port b to exchange heat with the environment and achieve refrigerant condensation. Then it flows back to the integrated valve island assembly through port a, passes through the one-way valve 3.4, and flows into the liquid receiver-drier tank through port g of the integrated valve island. Then it returns to the integrated valve island assembly through port h. Port h is connected to port d. The liquid refrigerant flows out from port d, expands and evaporates through the first electronic expansion valve 1.6, and then absorbs heat from the passenger compartment through the air conditioning evaporator 1.7 to achieve the air conditioning cooling function.

[0076] The corresponding thermal management mode is achieved through the design of the above structure and the control of thermal management components. The core integrated valve island assembly of the invention has eight connection ports (a, b, c, d, e, f, g, h) and three connection holes (5.1, 5.2, 5.3). Connection holes a, b, c, d, g, and h are for external refrigerant inlet / outlet connections, with diameters ranging from 6mm, 8mm, 10mm, 12mm, 16mm, to 20mm, respectively. The corresponding countersunk hole step heights are 1mm and 2mm. Hole a connects to hole g, and hole d connects to hole h. Port e is the mounting hole for the refrigerant electronic expansion valve 3.3, with diameters of 20mm, 24mm, 28mm, and 32mm. The angle between the central axis of this hole and the central axis of hole c is 30°, 40°, 50°, and 60°. Port f is the mounting hole for the refrigerant three-way valve 3.1. The diameter of this hole is 20mm, 23mm, 26mm, or 29mm. The angle between the central axis of port f and the central axis of port c is 80°, 90°, or 100°.

[0077] Hole 5.1 is a connecting hole between port C and port G, with a diameter of 5mm, 6mm, 7mm, or 8mm. Hole 5.2 is a connecting hole between port E and port A, with a diameter of 5mm, 6mm, 7mm, or 8mm. Hole 5.3 is a connecting hole between port E and port H, with a diameter of 5mm, 6mm, 7mm, or 8mm. In summary, the 8 connecting ports and 3 channels constitute the core structure of the integrated valve island of this invention.

[0078] Advantages of this invention:

[0079] 1. Effects of the invented direct and indirect heat pump systems: This invention utilizes two automotive heat pump thermal management systems. These systems maximize the use of ambient air and waste heat from the battery or electric drive system to heat the passenger compartment, which is part of the passenger compartment, battery and electric drive system, and ambient air thermal systems. This reduces the reliance on PTC heaters directly utilizing battery power for heating, thus increasing battery range and reducing energy consumption.

[0080] 2. Reduced space size: The integrated heat pump valve island system of this invention integrates the core functional components of the high-pressure side thermal management of the thermal management system architecture of this invention, and connects them using the space-integrated valve island. This centralized arrangement and control management of the layout of each system greatly reduces the space required for each system and improves the overall vehicle space layout efficiency.

[0081] 3. Reduced weight, cost, and maintenance: This invention reduces the number of connecting pipes and supports for each core component through the integrated layout of the integrated valve island system, thereby reducing the weight and cost caused by the piping, reducing the amount of refrigerant and coolant to be added, and reducing the system cost and weight.

[0082] 4. In after-sales maintenance, vulnerable components on the high-voltage side are integrated separately, making replacement and maintenance convenient and reducing after-sales maintenance costs.

[0083] The foregoing has shown and described the basic principles and main structural features of the present invention. The present invention is not limited to the above examples; various changes and modifications can be made without departing from the spirit and scope of the invention, and all such changes and modifications fall within the scope of the claimed invention. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. An integrated heat pump liquid storage and drying valve island system, characterized in that: The system includes an integrated valve island system, a compressor, an air conditioning heating system, an external heat exchanger, an air conditioning evaporator, and a battery-cooled evaporator, all connected to the integrated valve island system. The air conditioning evaporator is connected to the integrated valve island system via a first electronic expansion valve, and the battery-cooled evaporator is connected to the integrated valve island system via a second electronic expansion valve. The other ends of the air conditioning evaporator and the battery-cooled evaporator are respectively connected to the inlet end of the compressor. The integrated valve island system is used to realize the switching between cooling and heating modes of the integrated heat pump liquid storage drying valve island system; The integrated valve island system includes a liquid storage and drying tank located on the high-pressure side of the heat pump system, a valve island body, a refrigerant three-way valve, a refrigerant electronic expansion valve, and a refrigerant one-way valve. The liquid storage and drying tank and the valve island body are provided with refrigerant flow holes. The refrigerant three-way valve, the refrigerant electronic expansion valve, and the refrigerant one-way valve are respectively connected to the interface on the valve island body. The interfaces on the valve island body include a one-way valve interface, an external heat exchanger interface, a compressor interface, and an evaporator interface. The one-way valve interface is connected to the refrigerant electronic expansion valve and the external heat exchanger, respectively. The external heat exchanger interface is connected to the refrigerant three-way valve and the external heat exchanger, respectively. The compressor interface is connected to the refrigerant three-way valve, and the evaporator interface is connected to the air conditioner evaporator and the battery-cooled evaporator, respectively.

2. The integrated heat pump liquid storage and drying valve island system according to claim 1, characterized in that: When the integrated heat pump storage and drying valve island system enters the passenger compartment air source heat pump heating mode, the refrigerant after heat exchange from the compressed refrigerant enters the refrigerant three-way valve from the compressor interface. This valve is open to the left and right, but closed to the lower right. The refrigerant flows through the storage and drying tank, expands through the refrigerant electronic expansion valve, and then enters the external heat exchanger through the one-way valve interface. At this time, the refrigerant absorbs the waste heat of the air to heat the passenger compartment and realize the air source heat pump heating function.

3. The integrated heat pump liquid storage and drying valve island system according to claim 2, characterized in that: When the integrated heat pump storage and drying valve island system enters the crew cabin water source heat pump heating mode, the refrigerant after heat exchange from the compressed refrigerant enters the refrigerant three-way valve from the compressor interface. This valve is open to the left and right, but closed to the lower right. The refrigerant flows out of the evaporator interface through the storage and drying tank. At this time, the refrigerant electronic expansion valve is closed, and the outflowing refrigerant expands through the second electronic expansion valve and passes through the battery-cooled evaporator to absorb heat from the battery or electric drive coolant water source and returns to the compressor to realize the crew cabin water source heat pump heating function.

4. The integrated heat pump liquid storage and drying valve island system according to claim 3, characterized in that: When the integrated heat pump liquid storage and drying valve island system enters the passenger compartment cooling mode, the compressed refrigerant enters the refrigerant three-way valve from the compressor interface. This valve is closed to the left and right but open to the lower right. The refrigerant flows out through the external heat exchanger interface to the external heat exchanger for external heat exchange and condensation. The liquid refrigerant returns to the integrated liquid storage and drying valve island system through the one-way valve interface and is stored in the liquid storage and drying tank. At this time, the refrigerant electronic expansion valve is closed, and the liquid refrigerant flows out from the evaporator interface to the outside. It expands through the first electronic expansion valve and flows into the air conditioning evaporator to absorb heat from the passenger compartment air, thus achieving passenger compartment cooling.

5. The integrated heat pump liquid storage and drying valve island system according to claim 1, characterized in that: The air conditioning heating system is an air conditioning heater used in a direct heat pump system. The air conditioning heater is connected to the compressor outlet and the integrated valve island system.

6. The integrated heat pump liquid storage and drying valve island system according to claim 1, characterized in that: The air conditioning heating system consists of a water-cooled condenser and an air conditioning heater heat exchanger, used in an indirect heat pump system. The water-cooled condenser is connected to the compressor outlet and the integrated valve island system, respectively, and the air conditioning heater heat exchanger is connected to the water-cooled condenser.

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