Thermal management system with condensate water recycling function and control method

Abstract

The invention relates to a heat management system with a condensate water recycling function and a control method, and belongs to the technical field of vehicle heat management systems. The heat management system with the condensate water recycling function comprises an engine main cooling loop, and the engine main cooling loop comprises an engine and a radiator connected with the engine; the air conditioner refrigerating circuit comprises an evaporator, a compressor, a condenser and an expansion valve which are connected in series; the phase change energy storage pipeline comprises a water storage tank used for collecting condensate water generated by the evaporator and a phase change energy storage device connected with the water storage tank. Therefore, the phase change energy storage pipeline can collect the low-temperature condensate water generated by the evaporator through the water storage tank and control the low-temperature condensate water to flow through the phase change energy storage device, so that the phase change energy storage device stores cold energy and releases the cold energy to assist cooling when the engine is in high load, time domain transfer of energy is achieved, and the energy utilization efficiency is remarkably improved.

Description

Technical Field

[0001] The present application relates to the technical field of vehicle thermal management systems, and in particular to a thermal management system with condensed water recovery and utilization and a control method. Background Art

[0002] In the thermal management systems of complete vehicles currently on the market, the condensate drainage of the air-conditioning system is mostly discharged directly to the outside of the vehicle. In a high-temperature environment, the condensate generated on the surface of the evaporator is relatively low in temperature and is a relatively valuable cold source, but in the prior art, it is usually discharged directly into the air, resulting in a waste of energy. For example, patent CN111674232A discloses a vehicle condensate recovery device, including a condenser shell, a condenser core, a recovery device and a water guide structure, which can realize the recovery of condensate and use it to cool the condenser. However, this solution lacks an effective control method and cannot flexibly start or adjust the use of condensate according to actual needs, resulting in limited energy-saving effects.

[0003] While some existing technologies attempt to recycle condensed water, they often suffer from incomplete control strategies. For example, condensed water usage cannot be dynamically adjusted based on vehicle operating conditions and ambient temperature, resulting in low energy efficiency. Furthermore, existing technologies lack mechanisms for storing and reusing condensed water cooling, making it difficult to address issues such as short-term engine cooling at excessively high loads, delayed cab heating after shutdown, and rapid temperature increases during cold starts. These shortcomings limit further improvements in thermal management systems in terms of energy efficiency and comfort.

[0004] Therefore, a thermal management system and control method that can efficiently recycle condensed water is urgently needed to address the energy waste, inflexible control, and time-domain imbalance of hot and cold energy in existing technologies. By optimizing the system architecture and control strategy, on-demand use of condensed water and energy storage can be achieved, thereby improving the energy efficiency and adaptability of the vehicle thermal management system. Summary of the Invention

[0005] In response to the deficiencies or one of the deficiencies raised in the above-mentioned background technology, the embodiments of the present application provide a thermal management system and control method with condensed water recycling and utilization, which can realize the on-demand use of collected condensed water, alleviate the problem of time-domain imbalance of thermal management energy, and effectively improve the energy-saving effect and adaptability of the thermal management system of the whole vehicle.

[0006] In a first aspect, an embodiment of the present application provides a thermal management system with condensed water recycling, comprising: an engine primary cooling circuit, the engine cooling circuit comprising an engine and a radiator connected to the engine; An air conditioning refrigeration circuit, comprising an evaporator, a compressor, a condenser and an expansion valve connected in series; A phase-change energy storage pipeline includes a water tank for collecting condensed water generated by the evaporator, and a phase-change energy storage device connected to the water tank. The phase-change energy storage device is connected to the engine and is used to store the cold energy of the condensed water to assist in cooling the engine.

[0007] On the first aspect, in some embodiments, the phase change energy storage device is provided with a first flow channel and a second flow channel that are independent of each other, and a phase change material for exchanging heat between the fluid in the first flow channel and the fluid in the second flow channel, the first flow channel is connected to the water tank, and the second flow channel is connected to the engine.

[0008] In a first aspect, in some embodiments, the phase change energy storage device includes a housing, a first diverter chamber and a first confluence chamber, and a second diverter chamber and a second confluence chamber are provided in the housing, a plurality of pipes communicating with the first diverter chamber and the first confluence chamber are provided at intervals in the housing, and channels communicating with the second diverter chamber and the second confluence chamber are formed between adjacent pipes; A capsule is provided in the channel, which is in contact with the surface of the pipeline and contains the phase change material. The first diversion cavity is connected to a first inlet, the first confluence cavity is connected to a first outlet, the second diversion cavity is connected to a second inlet, and the second confluence cavity is connected to a second outlet.

[0009] On the first aspect, in some embodiments, a heater core and a first water pump are connected between the phase change energy storage device and the engine, and the heater core, the first water pump, the phase change energy storage device and the engine together form an air conditioning and heating circuit for heating the passenger compartment.

[0010] In the first aspect, in some embodiments, the air conditioning and heating circuit is further provided with a multi-way valve, wherein the multi-way valve has a first state and a second state; When the multi-way valve is in the first state, the heater core, the first water pump, and the phase-change energy storage device form a first communication circuit and are independent of the engine; When the multi-way valve is in the second state, the heater core, the first water pump, the phase-change energy storage device and the engine together form a second communication circuit.

[0011] In a first aspect, in some embodiments, the engine main cooling circuit is connected in parallel with the air conditioning and heating circuit through the engine, and an engine water pump is connected between the radiator and the engine.

[0012] On the first aspect, in some embodiments, the phase change energy storage pipeline also includes a second water pump connected to the water tank outlet, and a condensation water atomization device connected to the second flow channel outlet, and the condensation water atomization device is used to spray and cool the condenser and / or radiator.

[0013] In a second aspect, an embodiment of the present application provides a control method for a thermal management system with condensed water recycling, using the thermal management system with condensed water recycling described in the above embodiment, the control method includes: The condensed water generated by the evaporator is collected in a water storage tank, and the second water pump is turned on to allow the condensed water to flow through the phase change energy storage device, which stores cold energy. When the liquid in the engine cooling channel exceeds a preset threshold, the multi-way valve is switched to the second state, and the first water pump is turned on to circulate the liquid in the engine cooling channel through the phase change energy accumulator. The phase change energy accumulator releases cold energy to circulate and cool the liquid in the engine cooling channel.

[0014] In a second aspect, in some embodiments, the control method further comprises: Switch the multi-way valve to the second state, start the first water pump, and close the second water pump. Use the heat generated by the engine to heat the liquid in its cooling channel. The liquid circulates through the phase change accumulator, which stores heat. During the next cold start of the vehicle after the engine stops, the multi-way valve is switched to the first state and the first water pump is turned on, so that the liquid circulates between the heater core and the phase-change energy accumulator without passing through the engine. The phase-change energy accumulator releases heat, causing the liquid passing through the heater core to heat up rapidly. Or when the engine stops and the vehicle is running purely on electricity, the multi-way valve is switched to the first state, and the first water pump is kept on, and the phase change energy storage device is used to release heat to slow down the cooling rate of the liquid passing through the heater core.

[0015] In a second aspect, in some embodiments, the control method further includes: The water storage tank is used to collect the condensed water generated by the evaporator, and the second water pump is turned on to pump the condensed water into the condensed water atomizing device through the second water pump. The condensed water is atomized by the condensed water atomizing device and then sprayed onto the surface of the condenser and / or radiator for cooling.

[0016] The beneficial effects of the technical solution provided by this application include: An embodiment of the present application provides a thermal management system and control method with condensed water recycling. The engine cooling circuit includes an engine and a radiator connected to the engine; the air-conditioning refrigeration circuit includes an evaporator, a compressor, a condenser and an expansion valve connected in series; the phase change energy storage pipeline includes a water tank for collecting condensed water generated by the evaporator, and a phase change energy storage device connected to the water tank, and the phase change energy storage device is connected to the engine.

[0017] Therefore, the phase-change energy storage pipeline collects the low-temperature condensed water produced by the evaporator through a water storage tank, controls the flow of this low-temperature condensed water through the phase-change energy storage device, and stores cold energy in the phase-change energy storage device. This cold energy is released to assist in cooling the engine when the engine is under high load, thus achieving time-domain energy transfer and significantly improving energy utilization efficiency. The phase-change energy storage device is connected to the engine to form an auxiliary cooling circuit, which works in conjunction with the engine's main cooling circuit to significantly improve the cooling effect under high-load engine conditions. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the following briefly introduces the drawings required for use in the description of the embodiments. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0019] Figure 1 This is a structural block diagram of the thermal management system according to an embodiment of the present application; Figure 2 This is a schematic structural diagram of a phase change energy storage device according to an embodiment of the present application; Figure 3 This is a flow chart of the thermal management system according to an embodiment of the present application.

[0020] In the accompanying drawings, the components represented by the reference numerals are as follows: 1. Engine; 2. Evaporator; 3. Water tank; 4. Phase change energy accumulator; 41. Shell; 411. First diversion chamber; 412. First confluence chamber; 413. Second diversion chamber; 414. Second confluence chamber; 42. Pipeline; 43. Channel; 44. Capsule; 45. First inlet; 46. First outlet; 47. Second inlet; 48. Second outlet; 5. Heater core; 6. First water pump; 7. Multi-way valve; 8. Radiator; 9. Compressor; 10. Condenser; 11. Expansion valve; 12. Second water pump; 13. Condensate atomization device. DETAILED DESCRIPTION

[0021] To make the purpose, technical solutions, and advantages of the embodiments of this application more clear, the technical solutions in the embodiments of this application will be clearly and completely described below in conjunction with the drawings in the embodiments of this application. Obviously, the described embodiments are part of the embodiments of this application, not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of this application.

[0022] In response to the deficiencies or one of the deficiencies raised in the above-mentioned background technology, the embodiments of the present application provide a thermal management system and control method with condensed water recycling and utilization, which can realize the on-demand use of collected condensed water, alleviate the problem of time-domain imbalance of thermal management energy, and effectively improve the energy-saving effect and adaptability of the thermal management system of the whole vehicle.

[0023] See also Figures 1 to 3 As shown, the first aspect of the embodiment of the present application provides a thermal management system with condensed water recycling, comprising: The engine main cooling circuit includes an engine 1 and a radiator 8 connected to the engine 1; The air conditioning refrigeration circuit includes an evaporator 2, a compressor 9, a condenser 10 and an expansion valve 11 connected in series; Phase change energy storage pipeline, the phase change energy storage pipeline includes a water tank 3 for collecting condensed water generated by the evaporator 2, and a phase change energy storage device 4 connected to the water tank 3. The phase change energy storage device 4 is connected to the engine 1 and is used to store the cold energy of the condensed water to assist in cooling the engine 1.

[0024] The phase change energy storage pipeline of the embodiment of the present application can collect the low-temperature condensed water generated by the evaporator 2 through the water storage tank 3, control the low-temperature condensed water to flow through the phase change energy storage device 4, so that the phase change energy storage device 4 stores cold energy, and releases the cold energy to assist in cooling when the engine 1 is under high load, thereby realizing the time domain transfer of energy and significantly improving energy utilization efficiency.

[0025] For example, the phase-change energy accumulator 4 of this embodiment employs a dual-channel design: the first channel is for condensed water, and the second channel is for engine coolant circulation. The inlet of the water storage tank 3 is connected to the condensed water outlet of the evaporator 2. When the air conditioning refrigeration circuit is operating, the condensed water produced by the evaporator 2 flows into the water storage tank 3 under the action of gravity.

[0026] The outlet of the water tank 3 is connected to the inlet of the first flow channel. A pump can be installed, or gravity can be used to force the condensed water collected in the water tank 3 to flow through the first flow channel, allowing the phase-change energy accumulator 4 to store cold energy. When auxiliary cooling of the engine 1 is required, the pump in the auxiliary cooling circuit of the engine is controlled to operate, utilizing the cold energy stored in the phase-change energy accumulator 4 to assist in cooling the engine 1.

[0027] Since the main engine cooling circuit can meet the normal heat dissipation of the engine 1, when the air conditioning refrigeration circuit is working, the water tank 3 has enough time to collect condensed water and use the phase change energy storage device 4 to store the cold energy of the condensed water. When the engine 1 needs auxiliary cooling, the phase change energy storage device 4 is used to release cold energy to assist in cooling the engine 1. This on-demand control strategy not only ensures the cooling effect but also avoids energy waste, and is particularly suitable for short-term high-load engine conditions.

[0028] In some other embodiments, the phase change energy storage device 4 may adopt a single-channel design, with two-position three-way valves installed at the two end channel openings of the single channel respectively; the remaining two ports of the two-position three-way valve on one side are connected to the outlet of the water tank 3 and the inlet of the engine cooling channel respectively; the remaining two ports of the two-position three-way valve on the other side, one is connected to the outlet of the engine cooling channel to form a circulation loop, and the other is used as a condensed water outlet.

[0029] Pump bodies can be connected in series between the engine 1 and the phase-change energy accumulator 4, as well as between the phase-change energy accumulator 4 and the water tank 3 to provide delivery power. By controlling the two-position three-way valves on both sides to switch the passages, the condensed water can first flow through the single flow channel of the phase-change energy accumulator 4, so that the phase-change energy accumulator 4 can store the cold energy of the condensed water. Then, by controlling the two-position three-way valves on both sides to switch the passages, the single flow channel of the phase-change energy accumulator 4 can be connected in series with the engine cooling flow channel, and the pump body can be used to circulate the coolant to achieve the phase-change energy accumulator 4 releasing cold energy to assist in cooling the engine 1.

[0030] It should be noted that the phase change energy storage device 4 in this embodiment is connected to the engine 1 to form an engine auxiliary cooling circuit, which is independent of the engine main cooling circuit and works in conjunction with the engine main cooling circuit to significantly improve the cooling effect of the engine under high load conditions.

[0031] Specifically, the engine main cooling circuit drives the coolant through the engine 1's own engine water pump and performs conventional heat dissipation through the radiator 8. Under high load conditions, the phase change energy storage device 4 provides additional cooling capacity through the engine auxiliary cooling circuit. The combination of the two can significantly reduce the energy consumption of the radiator fan while avoiding the risk of overheating of the engine 1.

[0032] In some optional embodiments, see Figures 1 to 3 As shown, an embodiment of the present application provides a thermal management system with condensed water recycling, and the phase change energy storage device 4 of the thermal management system with condensed water recycling is provided with a first flow channel and a second flow channel that are independent of each other, and a phase change material for exchanging heat between the fluid in the first flow channel and the fluid in the second flow channel, the first flow channel is connected to the water tank 3, and the second flow channel is connected to the engine 1.

[0033] The phase-change energy storage device 4 of the present embodiment utilizes a dual-channel design. The first channel is for condensed water, while the second channel is for circulating engine 1 coolant. The two channels exchange heat indirectly via phase-change material. This structure prevents direct mixing of hot and cold media while leveraging the high latent heat of the phase-change material to achieve efficient energy storage and release. This addresses the energy waste, inflexible control, and temporal imbalance of hot and cold energy in traditional thermal management systems.

[0034] Specifically, it can realize the recovery of low-temperature condensed water waste cold when the air-conditioning refrigeration system is running at high temperature, and through reasonable calibration, the rotation speed of the fan and compressor 9 can be reduced to save energy; at the same time, it can realize the storage of recovered cold, realize the energy shift in the time domain, improve the power utilization of the power system, and improve the environmental adaptability of the whole vehicle; when running at low temperature, it can realize the storage of heat while realizing the waste heat heating of the engine 1, realize the energy shift in the time domain, ensure the rapid heating of the passenger compartment or maintain the temperature of the passenger compartment during pure electric or cold start, and improve the cabin comfort and energy saving.

[0035] In some optional embodiments, see Figures 1 to 3 As shown, an embodiment of the present application provides a thermal management system with condensed water recycling. The phase change energy storage device 4 of the thermal management system with condensed water recycling includes a shell 41. A first diverter cavity 411 and a first confluence cavity 412, as well as a second diverter cavity 413 and a second confluence cavity 414 are provided in the shell 41. A plurality of pipes 42 connecting the first diverter cavity 411 and the first confluence cavity 412 are provided at intervals in the shell 41. Channels 43 connecting the second diverter cavity 413 and the second confluence cavity 414 are formed between adjacent pipes 42. A capsule 44 is provided in the channel 43, which is in contact with the surface of the pipe 42 and contains phase change material. The first diversion chamber 411 is connected to the first inlet 45, the first confluence chamber 412 is connected to the first outlet 46, the second diversion chamber 413 is connected to the second inlet 47, and the second confluence chamber 414 is connected to the second outlet 48.

[0036] The phase-change energy accumulator 4 in this embodiment utilizes a multi-pipe parallel structure, with capsules 44 encapsulating the phase-change material and closely fitting the walls of pipes 42 to maximize heat exchange area. This ensures efficient heat exchange between the condensate flowing through pipes 42 and the phase-change material, as well as between the engine coolant flowing within channels 43. This design enables efficient energy storage and transfer within a compact space, meeting the vehicle's requirements for a lightweight and miniaturized thermal management system.

[0037] Specifically, the housing 41 of this embodiment includes two symmetrically arranged semi-cylindrical shells, with the rectangular large surfaces of the two semi-cylindrical shells facing each other. A rectangular shell is fixed between the two semi-cylindrical shells, and the two ends of the rectangular shell are sealed by the semi-cylindrical shells. A plurality of equally spaced flat tubes are fixed inside the rectangular shell along the length direction of the semi-cylindrical shells, and the ends of the flat tubes are respectively fixedly connected to the rectangular large surfaces of the two semi-cylindrical shells. The two semi-cylindrical shells are interconnected through the plurality of flat tubes. The spaces inside the above-mentioned two semi-cylindrical shells respectively form a first diversion chamber 411 and a first confluence chamber 412, and the flat tube is a pipe 42 connecting the first diversion chamber 411 and the first confluence chamber 412; the large surfaces of the flat tubes are arranged opposite to each other and are spaced to form a channel 43, and a capsule 44 containing phase change material is bonded and fixed on the large surface of one side of the flat tube. The two side walls of the rectangular shell protrude outward perpendicular to the large surface of the flat tube to form a second diversion chamber 413 and a second confluence chamber 414 respectively, and the two semi-cylindrical shells are respectively connected with joints to form a first inlet 45 and a first outlet 46, and one end of the second diversion chamber 413 and the second confluence chamber 414 are respectively connected with joints to form a second inlet 47 and a second outlet 48.

[0038] When in use, the first inlet 45 acts as a condensed water inlet, and the first outlet 46 acts as a condensed water outlet; the second inlet 47 acts as a warm air water inlet, and the second outlet 48 acts as a warm air water outlet. It should be noted that since the warm air core 5 can be connected to the engine cooling channel through the multi-way valve 7, the warm air water mentioned here is also the cooling water passing through the engine cooling channel.

[0039] For example, the outer shell of capsule 44 can be made of high-density polyethylene (HDPE) or polypropylene (PP). These materials offer excellent corrosion resistance, mechanical strength, and moldability, and are capable of withstanding the volume changes of the phase change material during its transition, while ensuring long-term leakage resistance. The outer shell is typically designed to have a wall thickness between 0.5 and 1.0 mm to balance structural strength and heat transfer efficiency.

[0040] The phase change material inside capsule 44 can be a graphite- or paraffin-based composite material, with a phase change temperature between 50-70°C and a latent heat of approximately 200 kJ / kg. Specifically, the phase change energy storage device 4 is coated with a thermally insulating material, making it nearly thermally insulated from the outside world. Condensed water flows in through first inlet 45 and out through first outlet 46. When the condensed water temperature is below 50°C, the phase change material transforms from liquid to solid, releasing heat. Warm water flows in through second inlet 47 and out through second outlet 48. When the warm water temperature is above 70°C, the phase change material transforms from solid to liquid, absorbing heat. Condensed water and warm water can pass through the energy storage device separately or simultaneously.

[0041] In some optional embodiments, see Figures 1 to 3 As shown, an embodiment of the present application provides a thermal management system with condensed water recycling, wherein a heater core 5 and a first water pump 6 are connected between the phase change energy storage device 4 and the engine 1 of the thermal management system with condensed water recycling, and the heater core 5, the first water pump 6, the phase change energy storage device 4 and the engine 1 together form an air conditioning and heating circuit for heating the passenger compartment.

[0042] The air conditioning and heating circuit in this embodiment integrates engine waste heat recovery and phase-change energy storage, with coolant circulation driven by a first water pump 6. In low-temperature environments, engine coolant flowing through the phase-change energy accumulator 4 stores heat, which is then used by the heater core 5 to provide heating for the passenger compartment. In pure electric mode, the phase-change energy accumulator 4 releases the stored heat to maintain the temperature of the heater core 5, significantly improving winter passenger cabin comfort and reducing energy consumption.

[0043] Specifically, the heater core 5 and evaporator 2 of the present application are both installed in an air conditioning cabinet, which is equipped with a fan and air ducts that respectively accommodate the heater core 5 and evaporator 2, as well as a damper for controlling the airflow path. By controlling the damper and coordinating with the fan, airflow can be directed solely through the heater core 5 or the evaporator 2. When the evaporator 2 cooperates with the fan to blow cold air, since no airflow passes through the heater core 5, the air conditioning heating circuit is used as an auxiliary engine cooling circuit to assist in cooling the engine 1, with little impact on the air conditioning cooling air.

[0044] Furthermore, the use of the air conditioning heating circuit as the auxiliary engine cooling circuit to assist in cooling the engine 1 is only controlled under high-load conditions of the engine 1. High-load conditions of the engine 1 are generally short-lived, requiring only a short period of time for the auxiliary engine cooling circuit to assist in cooling the engine 1. Based on this consideration, the use of the air conditioning heating circuit as the auxiliary engine cooling circuit to assist in cooling the engine 1 for a short period of time also has a relatively small impact on the air conditioning cooling air flow.

[0045] In some other embodiments, if space permits, the heater core 5 and the evaporator 2 can be respectively arranged in different spaces, and fans can be installed separately to coordinate the air outlet. The air conditioning heating circuit can be used as an auxiliary engine cooling circuit to assist in cooling the engine 1 without affecting the air conditioning cooling wind.

[0046] It should be noted that the phase-change energy storage pipeline of the embodiment of the present application collects the low-temperature condensed water produced by the evaporator 2 through the water storage tank 3, and uses the phase-change energy storage device 4 to store cold or heat to achieve the time domain transfer of energy. The phase-change energy storage device 4 is connected to the cooling flow channel of the engine 1, and can release cold energy to assist in cooling when the engine 1 is under high load, or store the waste heat of the engine 1 in a low temperature environment for subsequent heating, thereby significantly improving energy utilization efficiency. Through the storage and reuse mechanism of the condensed water cold energy, the problems of short-term ultra-high load cooling of the engine, delayed heating of the cab after shutdown, and rapid heating during cold start of the vehicle are solved.

[0047] In some optional embodiments, see Figures 1 to 3 As shown, the embodiment of the present application provides a thermal management system with condensed water recycling. The air conditioning and heating circuit of the thermal management system with condensed water recycling is further provided with a multi-way valve 7, and the multi-way valve 7 has a first state and a second state; When the multi-way valve 7 is in the first state, the heater core 5, the first water pump 6, and the phase-change energy storage device 4 form a first communication circuit and are independent of the engine 1; When the multi-way valve 7 is in the second state, the heater core 5 , the first water pump 6 , the phase-change energy storage device 4 and the engine 1 together form a second communication circuit.

[0048] The multi-way valve 7 of this embodiment enables flexible switching of the heating circuit. The first state applies to pure electric mode or cold start after engine 1 is shut down, with independent heating provided by the phase-change energy storage device 4. The second state applies to waste heat recovery mode when the engine 1 is running, simultaneously heating the passenger compartment and charging the phase-change energy storage device 4. This switching strategy solves the problem of heating interruptions during engine start-stop and start-stop cycles in traditional thermal management systems.

[0049] Specifically, the multi-way valve 7 of the embodiment of the present application adopts a four-way valve, which has port a, port b, port c and port d; port a is connected to the inlet of the cooling water channel of the engine 1, port b is connected to the outlet of the cooling water channel of the engine 1, port c is connected to the inlet of the heater core 5, port d is connected to the outlet of the first water pump 6, the outlet of the heater core 5 is connected to the second inlet 47 of the phase change energy accumulator 4, and the second outlet 48 of the phase change energy accumulator 4 is connected to the inlet of the first water pump 6.

[0050] When the four-way valve is in the first state, port a and port b of the four-way valve are connected, and port c and port d are connected, so that the warm water output by the first water pump 6 can directly return to the heater core 5 without passing through the cooling water channel of the engine 1. Therefore, the phase change energy storage device 4 can be used to independently heat the heater core 5, ensuring that the passenger compartment heats up quickly or maintains the temperature of the passenger compartment during pure electric operation or cold start, thereby improving cabin comfort and energy saving effects.

[0051] When the four-way valve is in the second state, ports a and d of the four-way valve are connected, and ports b and c are connected, allowing the warm water output by the first water pump 6 to pass through the cooling water channel of the engine 1 before returning to the heater core 5. This allows the engine 1 to generate waste heat for heating while the phase-change energy storage device 4 stores heat, achieving energy shifting in the time domain and preparing for subsequent all-electric operation or cold start of the vehicle.

[0052] In some optional embodiments, see Figures 1 to 3 As shown, an embodiment of the present application provides a thermal management system with condensed water recycling. The engine main cooling circuit of the thermal management system with condensed water recycling is connected in parallel with the air-conditioning and heating circuit through the engine 1, and an engine water pump is connected between the radiator 8 and the engine 1.

[0053] The parallel cooling circuit design of this embodiment allows the engine's main cooling circuit to operate in conjunction with the air conditioning and heating circuit. The engine's water pump drives coolant through radiator 8 for conventional heat dissipation. Under high-load conditions, the phase-change energy storage device 4 provides additional cooling capacity through the air conditioning and heating circuit. This combination significantly reduces radiator fan energy consumption while preventing the risk of engine 1 overheating.

[0054] It should be noted that the radiator 8 and condenser 10 in this embodiment are equipped with fans to dissipate heat, and to meet the normal operating heat dissipation requirements of the radiator 8 and condenser 10, a three-way valve is connected in series to the main engine cooling circuit. The bypass port of the three-way valve is connected to an expansion kettle connected to the cooling channel of the engine 1. The expansion kettle is used to hold excess coolant and ensure system pressure stability. The cooling channel of the engine 1 is the water jacket of the engine 1 itself.

[0055] In some optional embodiments, see Figures 1 to 3 As shown, an embodiment of the present application provides a thermal management system with condensed water recycling. The phase change energy storage pipeline of the thermal management system with condensed water recycling also includes a second water pump 12 connected to the outlet of the water tank 3, and a condensed water atomization device 13 connected to the outlet of the second flow channel. The condensed water atomization device 13 is used to spray and cool the condenser 10 and / or the radiator 8.

[0056] The condensate atomizer 13 of the present embodiment atomizes the collected condensate via a second water pump 12 and sprays it onto the surface of the condenser 10 or radiator 8, utilizing the evaporative heat absorption effect to enhance heat dissipation. This condensate atomizer 13 utilizes an adjustable-angle atomizer nozzle that adjusts the spray target and flow rate based on system pressure and ambient temperature. Under high-temperature conditions, it prioritizes cooling the condenser 10 to reduce the load on the compressor 9, further improving the energy efficiency of the air conditioning system.

[0057] Exemplarily, the condensate atomizing spray device utilizes an adjustable-angle atomizing nozzle to adjust the spray angle. This angle is adjusted based on the air conditioning system's operating pressure and the engine system's temperature, with the condenser 10 or high-temperature radiator 8 being sprayed based on priority. A liquid level monitoring sensor is installed within the condensate storage tank 3. When the liquid level falls below the lower minimum mark (the lowest water level on the scale), an alarm is triggered, disabling the second water pump 12.

[0058] See also Figures 1 to 3 As shown, the second aspect of the embodiment of the present application provides a control method for a thermal management system with condensed water recycling. Using the thermal management system with condensed water recycling of the above embodiment, the control method includes: The condensed water generated by the evaporator 2 is collected in the water storage tank 3, and the second water pump 12 is turned on to allow the condensed water to flow through the phase change energy storage device 4, which stores cold energy. When the liquid in the cooling channel of the engine 1 exceeds a preset threshold, the multi-way valve 7 is switched to the second state, and the first water pump 6 is turned on, so that the liquid in the cooling channel of the engine 1 circulates through the phase change energy accumulator 4. The phase change energy accumulator 4 releases cold energy to circulate and cool the liquid in the cooling channel of the engine 1.

[0059] The control method of this embodiment monitors the engine 1 coolant temperature in real time, dynamically triggering the release of cooling energy from the phase-change energy storage device 4. When the temperature exceeds a threshold, the system automatically switches the state of the multi-way valve 7 and activates the first water pump 6, utilizing the stored cooling energy to assist in cooling the engine 1. This on-demand control strategy ensures effective cooling while avoiding energy waste, making it particularly suitable for short-term high-load conditions on the engine 1.

[0060] For example, when the temperature is higher than 30°C, the air-conditioning system enters the cooling state, and the condensed water temperature is lower, generally maintained below 15°C. When passing through the phase change heat storage device, the phase change material changes from liquid to solid, releases heat, and stores cold energy.

[0061] When the heat load of the engine 1 is high (such as high-load climbing), the four-way valve is controlled to connect ports a and b, and ports c and d, and the first water pump 6 starts to work. The hot water in the engine 1 circuit passes through the phase change accumulator 4, and the phase change material changes from solid to liquid, absorbing the short-term excessive heat load of the engine 1 and ensuring smooth operation of the system.

[0062] In the second aspect, in some optional embodiments: see Figures 1 to 3 As shown, an embodiment of the present application provides a control method for a thermal management system with condensed water recycling, and the control method for a thermal management system with condensed water recycling also includes: Switch the multi-way valve 7 to the second state, start the first water pump 6, and close the second water pump 12. Use the heat generated by the engine 1 when it is working to heat the liquid in its cooling channel. The liquid circulates through the phase change accumulator 4, which stores heat. When the vehicle is cold-started next time after the engine 1 stops, the multi-way valve 7 is switched to the first state, and the first water pump 6 is turned on, so that the liquid circulates between the heater core 5 and the phase-change energy accumulator 4 without passing through the engine 1. The phase-change energy accumulator 4 releases heat, causing the liquid passing through the heater core 5 to heat up quickly. Alternatively, when the engine 1 stops and the vehicle is running purely electrically, the multi-way valve 7 is switched to the first state, and the first water pump 6 is kept on, and the phase change accumulator 4 is used to release heat to slow down the cooling rate of the liquid passing through the heater core 5.

[0063] The thermal management strategy of this embodiment utilizes engine 1's waste heat across multiple time periods: storing heat when engine 1 is running and releasing it during cold starts or in pure electric mode. Through the intelligent switching of multi-way valve 7, the system maintains the passenger compartment temperature when engine 1 is not operating, resolving the cold-start heating delay issue of conventional vehicles while significantly extending the pure electric range of hybrid vehicles.

[0064] For example, during winter low-temperature thermal management system operation, the four-way valve's ports a and d, and ports b and c, are connected. This activates the first water pump 6 and stops the second water pump 12. During system operation, high-temperature water flows through the second inlet 47 and the second outlet 48 through the phase-change energy storage device 4. The phase-change material within the phase-change energy storage device 4 changes from solid to liquid, storing heat.

[0065] When the vehicle is cold-started next time after the engine 1 stops, the four-way valve is controlled to connect port a and port b, and port c and port d. The water temperature passing through the heater core 5 is low, and the phase change material in the phase change energy storage device 4 changes from liquid to solid to release heat, thereby quickly increasing and maintaining the temperature of the heater water path, achieving energy savings, and improving passenger compartment comfort.

[0066] When the thermal management system of the embodiment of the present application is applied in a hybrid vehicle, when the engine 1 stops working and runs purely on electricity, the four-way valve is controlled to connect ports a and b, and ports c and d, to slow down the cooling rate of the water temperature in the warm air circuit, thereby saving energy and improving passenger compartment comfort.

[0067] In the second aspect, in some optional embodiments: see Figures 1 to 3 As shown, an embodiment of the present application provides a control method for a thermal management system with condensed water recycling, and the control method for a thermal management system with condensed water recycling also includes: The condensed water generated by the evaporator 2 is collected in the water storage tank 3, and the second water pump 12 is turned on to pump the condensed water into the condensed water atomizing device 13 through the second water pump 12. The condensed water is atomized by the condensed water atomizing device 13 and then sprayed onto the surface of the condenser 10 and / or the radiator 8 for cooling.

[0068] The condensate spray control system in this embodiment uses a liquid level sensor to monitor the water level in the water tank 3 in real time, maximizing condensate utilization while ensuring safety. The system intelligently selects spray targets based on air conditioning pressure and engine 1 temperature, prioritizing the most pressing cooling needs. This adaptive control approach can further reduce fan and compressor 9 energy consumption compared to a fixed spray strategy.

[0069] Exemplarily, the condensate atomizing spray device can use an adjustable angle atomizing nozzle to achieve spray angle adjustment, intelligently adjust the spray angle according to the size of the air-conditioning system operating pressure P2 and the value of the engine system temperature T1, and spray the condenser 10 or the high-temperature radiator 8 according to priority.

[0070] Specifically, pressure sensors for detecting the operating pressure of the air-conditioning system and temperature sensors for detecting the refrigerant temperature are provided at the inlet and outlet of the compressor 9; a temperature sensor for detecting the coolant temperature is provided on the main cooling circuit of the engine, and a temperature sensor for detecting the warm air water temperature is provided at the inlet of the heater core 5; a liquid level sensor is provided in the water storage tank 3 for collecting condensed water, which alarms when the liquid level is lower than the lower liquid level min line (the lowest water level scale) and controls the second water pump 12 not to start.

[0071] The present invention provides a thermal management system with condensed water recycling, which includes the following steps when used: Step 1: System initialization and operation mode determination; After the vehicle is powered on, the thermal management system automatically initializes and checks the current environmental parameters. The system first determines the air conditioning operating mode: if a cooling request is detected (ambient temperature ≥ 30°C), compressor 9 is activated, entering condensate recovery mode; if a heating request is detected (ambient temperature ≤ 5°C), waste heat recovery mode is entered. Simultaneously, the liquid level in water tank 3 is monitored in real time. When the level falls below the minimum limit, a protection mechanism is triggered, disabling the second water pump 12.

[0072] Step 2: Recovery and utilization of condensed water under refrigeration conditions; When the system is in cooling mode, perform the following sub-steps: Control the four-way valve to switch to the ab and cd passage states, start the second cold water pump 12, and transport the low-temperature condensed water collected in the water storage tank 3 to the phase change energy storage device 4 for cold storage; According to the temperature and pressure sensor data installed in the circuit where the condenser 10 is located, the spray angle and flow rate of the condensate atomization device 13 are intelligently adjusted to give priority to spraying and cooling the condenser 10 on the high-pressure side; When the engine 1 coolant temperature T1 exceeds the first threshold value Tb (e.g., 110°C), the four-way valve is controlled to switch to the ad and bc passage states, the first water pump 6 is started, and the condensed water atomization device 13 is sprayed toward the radiator 8 for cooling. At the same time, the phase change energy storage device 4 is used to release cold energy to cool the engine coolant. When the engine 1 coolant temperature T1 is lower than the secondary threshold value Ta (eg, 105°C) and the compressor 9 outlet high pressure warning pressure P2 is higher than Pa (eg, 16 bar), the condensate atomizing device 13 sprays toward the condenser 10 for cooling.

[0073] Step 3: Waste heat recovery and heat management under heating conditions; When the system determines that it is in heating mode, the following sub-steps are executed: The four-way valve is controlled to switch to the ad and bc passage states, and the first water pump 6 is started. During the normal operation of the engine 1, the high-temperature coolant is pushed to flow through the phase change accumulator 4 for heat storage; When the vehicle enters cold start or pure electric mode, the four-way valve is controlled to switch to the ab and cd paths, maintaining the operation of the first water pump 6 (the second water pump 12 is in the off state in this mode), and the phase change energy storage device 4 releases the stored heat to provide continuous heating for the passenger compartment through the heater core 5; When the engine 1 is restarted, the four-way valve is controlled to switch back to the ad and bc passage states.

[0074] Step 4: System protection and troubleshooting; Real-time monitoring of key parameters: liquid level in water tank 3 (detected by liquid level sensor), phase change state of phase change material (through temperature gradient analysis), operating current of each water pump (overload protection), and four-way valve path status feedback signal.

[0075] When an abnormality is detected, the system automatically executes a degraded operation strategy: firstly ensuring the cooling needs of engine 1, then maintaining basic heating functions, and finally retaining the condensate collection capability and reporting the fault code through the vehicle network.

[0076] In the description of this application, it should be noted that the terms "upper" and "lower" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on this application. Unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or an indirect connection through an intermediate medium, or it can be internal communication between two elements. For those of ordinary skill in the art, the specific meanings of the above terms in this application can be understood according to the specific circumstances.

[0077] It should be noted that, in this application, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device comprising a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In the absence of further restrictions, an element defined by the sentence "comprising a ..." does not exclude the presence of other identical elements in the process, method, article or device comprising the element.

[0078] The foregoing is merely a list of specific embodiments of the present application, intended to enable those skilled in the art to understand or implement the present application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present application. Therefore, the present application is not limited to the embodiments shown herein, but is intended to conform to the broadest scope consistent with the principles and novel features of the present application.

Claims

1. A thermal management system with condensed water recycling, characterized in that: include: An engine main cooling circuit, the engine main cooling circuit comprising an engine (1) and a radiator (8) connected to the engine (1); An air conditioning refrigeration circuit, the air conditioning refrigeration circuit comprising an evaporator (2), a compressor (9), a condenser (10) and an expansion valve (11) connected in series; A phase-change energy storage pipeline, comprising a water storage tank (3) for collecting condensed water generated by an evaporator (2), and a phase-change energy storage device (4) connected to the water storage tank (3); the phase-change energy storage device (4) is connected to the engine (1) and is used to store the cold energy of the condensed water to assist in cooling the engine (1).

2. The thermal management system with condensed water recovery and utilization according to claim 1, characterized in that: The phase change energy storage device (4) is provided with a first flow channel and a second flow channel that are independent of each other, and a phase change material for performing heat exchange between the fluid in the first flow channel and the fluid in the second flow channel. The first flow channel is in communication with the water storage tank (3), and the second flow channel is connected to the engine (1).

3. The thermal management system with condensed water recovery and utilization according to claim 1 or 2, characterized in that: The phase change energy storage device (4) comprises a shell (41), a first diversion chamber (411) and a first confluence chamber (412), as well as a second diversion chamber (413) and a second confluence chamber (414) are provided in the shell (41), a plurality of pipes (42) communicating with the first diversion chamber (411) and the first confluence chamber (412) are provided at intervals in the shell (41), and channels (43) communicating with the second diversion chamber (413) and the second confluence chamber (414) are formed between adjacent pipes (42); A capsule (44) is provided in the channel (43), which is in contact with the surface of the pipe (42) and contains the phase change material. The first diversion cavity (411) is connected to a first inlet (45), the first confluence cavity (412) is connected to a first outlet (46), the second diversion cavity (413) is connected to a second inlet (47), and the second confluence cavity (414) is connected to a second outlet (48).

4. The thermal management system with condensed water recovery and utilization according to claim 2, characterized in that: A heater core (5) and a first water pump (6) are connected between the phase-change energy storage device (4) and the engine (1); the heater core (5), the first water pump (6), the phase-change energy storage device (4) and the engine (1) together form an air-conditioning and heating circuit for heating the passenger compartment.

5. The thermal management system with condensed water recovery and utilization according to claim 4, characterized in that: A multi-way valve (7) is also provided on the air conditioning and heating circuit, and the multi-way valve (7) has a first state and a second state; When the multi-way valve (7) is in the first state, the heater core (5), the first water pump (6), and the phase-change energy storage device (4) form a first communication loop and are independent of the engine (1); When the multi-way valve (7) is in the second state, the heater core (5), the first water pump (6), the phase-change energy storage device (4) and the engine (1) together form a second communication circuit.

6. The thermal management system with condensed water recovery and utilization according to claim 1 or 2, characterized in that: The engine main cooling circuit is connected in parallel with the air conditioning and heating circuit through the engine (1), and an engine water pump is connected between the radiator (8) and the engine (1).

7. The thermal management system with condensed water recovery and utilization according to claim 5, characterized in that: The phase-change energy storage pipeline further comprises a second water pump (12) in communication with the outlet of the water storage tank (3), and a condensed water atomizing device (13) in communication with the outlet of the second flow channel, wherein the condensed water atomizing device (13) is used for spraying and cooling the condenser (10) and / or the radiator (8).

8. A control method for a thermal management system with condensed water recycling, using the thermal management system with condensed water recycling according to claim 7, characterized in that: The control method includes: The condensed water generated by the evaporator (2) is collected by using a water storage tank (3), and the second water pump (12) is turned on to allow the condensed water to flow through the phase change energy storage device (4), and the phase change energy storage device (4) stores cold energy; When the liquid in the cooling channel of the engine (1) exceeds a preset threshold, the multi-way valve (7) is switched to the second state, and the first water pump (6) is turned on, so that the liquid in the cooling channel of the engine (1) circulates through the phase change energy storage device (4), and the phase change energy storage device (4) releases cold energy to circulate and cool the liquid in the cooling channel of the engine (1).

9. The control method of the thermal management system with condensed water recovery according to claim 8, characterized in that: The control method further includes: The multi-way valve (7) is switched to the second state, and the first water pump (6) is turned on, and the second water pump (12) is turned off, and the heat generated by the engine (1) when it is working is used to heat the liquid in the cooling channel thereof, and the liquid circulates through the phase change energy accumulator (4), and the phase change energy accumulator (4) stores heat; When the vehicle is cold-started next time after the engine (1) stops, the multi-way valve (7) is switched to the first state, and the first water pump (6) is turned on, so that the liquid circulates between the heater core (5) and the phase-change energy storage device (4) without passing through the engine (1). The phase-change energy storage device (4) releases heat, causing the liquid passing through the heater core (5) to heat up quickly; Alternatively, when the engine (1) stops working and the vehicle is running purely electrically, the multi-way valve (7) is switched to the first state, and the first water pump (6) is kept open, and the phase change energy storage device (4) is used to release heat to slow down the cooling rate of the liquid passing through the heater core (5).

10. The control method of the thermal management system with condensed water recovery according to claim 8, characterized in that: The control method further includes: The water storage tank (3) is used to collect the condensed water generated by the evaporator (2), and the second water pump (12) is turned on to pump the condensed water into the condensed water atomizing device (13) through the second water pump (12). The condensed water is atomized by the condensed water atomizing device (13) and then sprayed onto the surface of the condenser (10) and / or the radiator (8) for cooling.

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