Thermal management system for a vehicle

Abstract

The present application relates to a thermal management system of a vehicle. The thermal management system of the vehicle can include: a first coolant circuit including a range extender, a thermostat, a first pump, a heater, a heating core and a second pump connected by a first coolant line; and a second coolant circuit including a battery, a heat exchanger and a third pump connected by a second coolant line; wherein the first coolant circuit further includes a first coolant bypass line, a first end of the first coolant bypass line being connected to the first coolant line between the thermostat and the first pump, a second end of the first coolant bypass line being connected to the first coolant line between the heating core and the second pump; the heat exchanger is also provided in the first coolant bypass line to exchange heat between the first coolant circuit and the second coolant circuit.

Description

Technical Field

[0001] This invention relates to a vehicle thermal management system that can utilize the heat from the range extender to heat the vehicle interior and battery by controlling the state of the thermostat located in the range extender. Background Technology

[0002] Unlike pure electric vehicles, range-extended electric vehicles (REEVs) are equipped with an additional range extender that uses fuel to generate electricity. Compared to pure electric vehicles, REEVs offer the advantage of a smaller battery capacity and increased driving range. Furthermore, in cold environments, the heat generated by the range extender can be used for interior heating or battery heating.

[0003] However, range-extended electric vehicles may also experience thermal issues related to the range extender, such as heat dissipation of the range extender, as well as low fuel efficiency or high noise levels in cold environments. Furthermore, the batteries in range-extended electric vehicles also require heating / cooling to ensure proper charging and discharging performance.

[0004] Therefore, ensuring the heat dissipation of the range extender and fuel efficiency is crucial for the thermal management system of range-extended electric vehicles. Furthermore, ensuring the heating / cooling of the battery is also essential.

[0005] The information contained in the background section of this invention is only intended to enhance the understanding of the general background of this invention and should not be construed as an admission or in any way implying that such information constitutes prior art known to those skilled in the art. Summary of the Invention

[0006] The various aspects of the present invention are dedicated to solving the aforementioned problems in the prior art, and other technical problems not mentioned herein will be clearly understood by those skilled in the art through the following detailed description of the specification.

[0007] Various aspects of the present invention are dedicated to providing a vehicle thermal management system that can utilize the heat from the range extender to heat the vehicle interior and battery by controlling the state of a thermostat located in the range extender.

[0008] According to one aspect of the present invention, a vehicle thermal management system may include: a first coolant circuit and a second coolant circuit. The first coolant circuit includes a range extender, a thermostat, a first pump, a heater, a heating element, and a second pump connected via a first coolant line. The second coolant circuit includes a battery, a heat exchanger, and a third pump connected via a second coolant line. The first coolant circuit may further include a first coolant bypass line, a first end of which is connected to a first coolant line between the thermostat and the first pump, and a second end of which is connected to a first coolant line between the heating element and the second pump. A heat exchanger is also disposed on the first coolant bypass line to perform heat exchange between the first coolant circuit and the second coolant circuit.

[0009] Preferably, the first coolant circuit may further include: a second coolant bypass line, a third coolant bypass line, and a radiator. The first end of the second coolant bypass line may be connected to a thermostat, and the second end of the second coolant bypass line may be connected to a first coolant line upstream of the second pump. The first end of the third coolant bypass line may be connected to a thermostat, and the second end of the third coolant bypass line may be connected to a first coolant line upstream of the second pump. The radiator may be disposed on the third coolant bypass line for cooling the coolant flowing through the third coolant bypass line.

[0010] Preferably, the inlet port of the thermostat can be connected to the coolant outlet of the range extender, the first outlet port of the thermostat can be connected to the first coolant line upstream of the first end of the first coolant bypass line, the second outlet port of the thermostat can be connected to the first end of the second coolant bypass line, and the third outlet port of the thermostat can be connected to the first end of the third coolant bypass line.

[0011] Preferably, the vehicle's thermal management system may further include: an air conditioning refrigerant circuit, which includes a compressor, a condenser, a first expansion valve, and an evaporator connected via refrigerant lines. The air conditioning refrigerant circuit may further include a refrigerant branch line, a first end of which may be connected to a refrigerant line between the condenser and the first expansion valve, and a second end of which may be connected to a refrigerant line between the evaporator and the compressor.

[0012] Preferably, the second coolant circuit may further include: a three-way valve and a fourth coolant bypass line. The three-way valve may be located in the second coolant line between the battery and the heat exchanger. The first end of the fourth coolant bypass line may be connected to the second coolant line via the three-way valve, and the second end of the fourth coolant bypass line may be connected to the second coolant line between the heat exchanger and the third pump. The first port of the three-way valve may be connected to the second coolant line downstream of the battery, the second port of the three-way valve may be connected to the first end of the fourth coolant bypass line, and the third port of the three-way valve may be connected to the second coolant line upstream of the heat exchanger.

[0013] Preferably, the vehicle's thermal management system may further include: a battery cooler and a second expansion valve, wherein the battery cooler may be disposed on a fourth coolant bypass line and a refrigerant branch line; and the second expansion valve may be disposed on the refrigerant branch line upstream of the battery cooler.

[0014] Preferably, the vehicle's thermal management system may further include a controller configured to control the state of the thermostat based on the temperature of the coolant flowing out of the range extender and the temperature of the coolant flowing into the heater.

[0015] Preferably, when the thermostat is in the first state, the first and third outlet ports of the thermostat can be closed, and the second outlet port can be fully opened; the first pump can operate, causing the coolant flowing from the heating core to flow into the first coolant bypass line, and the coolant flowing from the first coolant bypass line to flow into the first pump; the second pump can operate, causing the coolant flowing from the second outlet port of the thermostat to flow into the second coolant bypass line, and the coolant flowing from the second coolant bypass line to flow into the second pump; the third pump can operate, causing the coolant in the second coolant circuit to circulate along the second coolant line; and the heater can operate to heat the coolant in the first coolant circuit.

[0016] Preferably, when the thermostat is in the second state, the first outlet port of the thermostat can gradually open until it is fully open as the temperature of the coolant flowing from the range extender increases, the second outlet port can be fully open, and the third outlet port can be closed; the first pump and the second pump can operate, so that the coolant flowing from the first outlet port of the thermostat flows along the first coolant line through the first pump, the heater, and the heating core, a portion of the coolant flowing from the heating core flows into the first coolant bypass line, and the remaining portion of the coolant flowing from the heating core flows into the second pump; and the coolant flowing from the second outlet port of the thermostat flows into the second coolant bypass line, and the coolant flowing from the second coolant bypass line flows into the second pump; the third pump can operate, so that the coolant in the second coolant circuit circulates along the second coolant line; the heater can be deactivated.

[0017] Preferably, when the thermostat is in the third state, the first outlet port of the thermostat can be fully opened, the second outlet port can gradually close until it is fully closed as the temperature of the coolant flowing from the range extender increases, and the third outlet port can gradually open until it is fully open as the temperature of the coolant flowing from the range extender increases; the first pump can be off and the second pump can be on, so that a portion of the coolant flowing from the first outlet port of the thermostat flows into the first coolant bypass line, the remaining portion of the coolant flowing from the first outlet port of the thermostat flows along the first coolant line through the first pump, heater and heating core, and the coolant flowing from the first coolant bypass line and the coolant flowing from the heating core flows together into the second pump along the first coolant line; and the coolant flowing from the third outlet port of the thermostat flows into the radiator on the third coolant bypass line, and the coolant flowing from the radiator flows into the second pump; the third pump can be on, so that the coolant in the second coolant circuit circulates along the second coolant line; the heater can be off.

[0018] Preferably, the controller can be configured to: control the operation of a three-way valve based on the temperature of the battery and the temperature of the coolant flowing out of the range extender, so that the coolant flowing out of the battery flows into a fourth coolant bypass line and / or heat exchanger; and control the operation of a second expansion valve based on the temperature of the battery, so that the refrigerant flowing into the battery cooler via the refrigerant branch line selectively expands. Attached Figure Description

[0019] The above and other objects, features, and advantages of the invention will become clearer from the following detailed description presented in conjunction with the accompanying drawings, in which:

[0020] Figure 1 A schematic diagram illustrating a vehicle thermal management system according to an exemplary embodiment of the present invention;

[0021] Figure 2 A schematic diagram illustrating the configuration of a vehicle's thermal management system according to an exemplary embodiment of the present invention;

[0022] Figure 3 This is a schematic diagram illustrating a vehicle thermal management system according to an exemplary embodiment of the present invention in a first mode;

[0023] Figure 4 This is a schematic diagram illustrating a vehicle thermal management system according to an exemplary embodiment of the present invention in a second mode;

[0024] Figure 5 A schematic diagram illustrating a vehicle thermal management system according to an exemplary embodiment of the present invention in a third mode;

[0025] Figure 6This is a schematic diagram illustrating how the opening degree of each outlet port of the thermostat in the thermal management system of a vehicle according to an exemplary embodiment of the present invention changes with the angle of the thermostat valve core.

[0026] It should be understood that the accompanying drawings are not drawn to scale, but rather illustrate various features that are presented in a slightly simplified manner to explain the basic principles of the invention. In the accompanying drawings of this invention, the same reference numerals denote the same or equivalent parts of the invention. Detailed Implementation

[0027] It should be understood that the term “vehicle” or “of a vehicle” or other similar terms used herein generally include motor vehicles, such as passenger cars including sport utility vehicles (SUVs), buses, trucks, passenger cars of various commercial vehicles, boats including various boats and ships, aircraft, etc., and includes hybrid vehicles, electric vehicles, plug-in hybrid electric vehicles, hydrogen-powered vehicles, and other alternative fuel vehicles (e.g., fuels derived from non-petroleum energy sources).

[0028] Although the exemplary embodiments are described as utilizing multiple units to perform the exemplary process, it should be understood that the exemplary process can also be performed by one or more modules. Furthermore, it will be understood that the term control unit / control unit refers to a hardware device including a memory and a processor. The memory is configured to store modules, and the processor is specifically configured to execute said modules to perform one or more processes further described below.

[0029] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the invention. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It is further understood that when the terms “comprising” and / or “including” are used in this specification, they specifically refer to the presence of the stated features, values, steps, operations, elements, and / or components, but do not exclude the presence or additional presence of one or more other features, values, steps, operations, elements, components, and / or combinations thereof. As used herein, the term “and / or” includes any and / or all combinations of one or more of the associated enumerations.

[0030] A vehicle thermal management system according to an exemplary embodiment of the present invention will now be described with reference to the accompanying drawings.

[0031] Figure 1 This is a schematic diagram illustrating a vehicle thermal management system according to an exemplary embodiment of the present invention. Figure 2 This is a schematic diagram illustrating the configuration of a vehicle's thermal management system according to an exemplary embodiment of the present invention. The following will be combined with... Figure 1 and Figure 2A thermal management system for a vehicle according to an exemplary embodiment of the present invention will be described in detail.

[0032] like Figure 1 As shown, the thermal management system of a vehicle according to an exemplary embodiment of the present invention may include: a first coolant circuit 10 and a second coolant circuit 20.

[0033] In an exemplary embodiment, the first coolant circuit 10 may include: a range extender 12, a thermostat 13, a first pump 14, a heater 15, a heating element 16, and a second pump 17 connected via a first coolant line 11.

[0034] Specifically, the range extender 12 can be installed in a range-extended electric vehicle to generate electricity through the combustion of fuel, thereby providing power to the electric vehicle.

[0035] The thermostat 13 can be an intelligent electronic thermostat (ITM). The thermostat 13 can have one inlet port and three outlet ports. The inlet port of the thermostat 13 can be connected to the coolant outlet of the range extender 12, allowing coolant flowing directly from the range extender 12 into the thermostat 13. The outlet ports of the thermostat 13 can include a first outlet port ①, a second outlet port ②, and a third outlet port ③. As an example, the opening degree of each outlet port of the thermostat 13 can be controlled by controlling the actuator of the thermostat 13.

[0036] The first pump 14 may be an electric pump used to circulate coolant in the first coolant line 11.

[0037] Heater 15 may be an electric heater (e.g., a PTC heater) for heating the coolant in the first coolant line 11.

[0038] The heating element 16 can be installed inside the heating ventilation and air conditioning (HVAC) module (not shown) of the vehicle air conditioning system to heat the air introduced into the vehicle.

[0039] The second pump 17 may be an electric pump used to circulate coolant in the first coolant line 11.

[0040] Furthermore, the first coolant circuit 10 may further include multiple coolant bypass lines. In an exemplary embodiment, the coolant bypass lines may include: a first coolant bypass line 31, a second coolant bypass line 32, and a third coolant bypass line 33.

[0041] The first end of the first coolant bypass line 31 can be connected to the first coolant line 11 between the thermostat 13 and the first pump 14, and the second end of the first coolant bypass line 31 can be connected to the first coolant line 11 between the heating core 16 and the second pump 17. Specifically, the first end of the first coolant bypass line 31 can be connected to the first outlet port ① of the thermostat 13.

[0042] The first end of the second coolant bypass line 32 can be connected to the second outlet port ② of the thermostat 13, and the second end of the second coolant bypass line 32 can be connected to the first coolant line 11 upstream of the second pump 17.

[0043] Coolant flowing out of the range extender 12 and into the second coolant bypass line 32 via the second outlet port ② of the thermostat 13 can flow directly back to the range extender 12 via the second coolant bypass line 32 and the first coolant line 11. When the temperature of the coolant flowing out of the range extender 12 is low, the coolant can circulate in the loop formed by the second coolant bypass line 32 and a portion of the first coolant line 11, thereby gradually warming up the range extender 12.

[0044] The first end of the third coolant bypass line 33 can be connected to the third outlet port ③ of the thermostat 13, and the second end of the third coolant bypass line 33 can be connected to the first coolant line 11 upstream of the second pump 17.

[0045] A radiator 18 can be installed on the third coolant bypass line 33. In the radiator 18, the coolant flowing from the range extender 12 and into the third coolant bypass line 33 via the third outlet port ③ of the thermostat 13 can be cooled through heat exchange with the outside air. The cooled coolant can flow back to the range extender 12 via the third coolant bypass line 33 and the first coolant line 11. When the temperature of the coolant flowing out of the range extender 12 is too high, the coolant can circulate in the loop formed by the third coolant bypass line 33 and a portion of the first coolant line 11, thereby cooling the range extender 12.

[0046] In an exemplary embodiment, the second coolant circuit 20 may include a battery 22, a three-way valve V, a heat exchanger 23, and a third pump 24 connected via a second coolant line 21.

[0047] Specifically, battery 22 can be a high-voltage battery that serves as a power source for an electric vehicle.

[0048] The three-way valve V can be installed on the second coolant line 21 between the battery 22 and the heat exchanger 23.

[0049] Heat exchanger 23 is a heat exchanger used to exchange heat between the coolant in the first coolant circuit 10 and the coolant in the second coolant circuit 20.

[0050] The third pump 24 may be an electric pump used to circulate coolant in the second coolant line 21.

[0051] In addition, the second coolant circuit 20 may further include a fourth coolant bypass line 25.

[0052] The first end of the fourth coolant bypass line 25 can be connected to the second coolant line 21 between the battery 22 and the heat exchanger 23 via a three-way valve V, and the second end of the fourth coolant bypass line 25 can be connected to the second coolant line 21 between the heat exchanger 23 and the third pump 24.

[0053] The first port of the three-way valve V can be connected to the second coolant line 21 downstream of the battery 22, the second port of the three-way valve V can be connected to the first end of the fourth coolant bypass line 25, and the third port of the three-way valve V can be connected to the second coolant line 21 upstream of the heat exchanger 23. By operating the three-way valve V, the coolant flowing from the battery 22 can be selectively directed into the heat exchanger 23 and / or the fourth coolant bypass line 25. Specifically, the operation of the three-way valve V can be controlled based on the temperature of the battery 22 and the temperature of the coolant flowing from the range extender 12.

[0054] Furthermore, the vehicle thermal management system according to an exemplary embodiment of the present invention may further include an air conditioning refrigerant circuit 40. The air conditioning refrigerant circuit 40 may include a compressor 42, a condenser 43, a first expansion valve TXV, and an evaporator 44 connected via a refrigerant line 41.

[0055] Compressor 42 can compress the refrigerant to a high temperature and high pressure state.

[0056] The condenser 43 can condense the high-temperature, high-pressure refrigerant flowing from the compressor 42 through heat exchange.

[0057] The first expansion valve TXV can be a mechanical expansion valve, which can expand the condensed refrigerant.

[0058] Evaporator 44 can evaporate the expanded refrigerant flowing out from the first expansion valve TXV through heat exchange.

[0059] Furthermore, the air conditioning refrigerant circuit 40 may further include a refrigerant branch line 45. The first end of the refrigerant branch line 45 may be connected to the refrigerant line 41 between the condenser 43 and the first expansion valve TXV, and the second end of the refrigerant branch line 45 may be connected to the refrigerant line 41 between the evaporator 44 and the compressor 42.

[0060] Furthermore, the thermal management system of a vehicle according to an exemplary embodiment of the present invention may further include a battery cooler 50 and a second expansion valve EXV.

[0061] The battery cooler 50 can be installed in the fourth coolant bypass line 25 and in the refrigerant branch line 45. The battery cooler 50 can be a heat exchanger for heat exchange between the coolant and the refrigerant.

[0062] The second expansion valve EXV can be installed on the refrigerant branch line 45 upstream of the battery cooler 50. The second expansion valve EXV can be an electronic expansion valve, which can selectively expand the refrigerant flowing into the battery cooler 50.

[0063] The coolant, whose temperature rises as it flows through battery 22, can flow into the fourth coolant bypass line 25 via the three-way valve V. When the refrigerant expands under the second expansion valve EXV, the coolant flowing through the fourth coolant bypass line 25 can exchange heat with the expanded refrigerant flowing through the refrigerant branch line 45 in the battery cooler 50. The coolant can be cooled, and the cooled coolant can be used to cool battery 22. Therefore, the refrigerant in the air conditioning refrigerant circuit 40 can be used to cool battery 22.

[0064] Furthermore, the vehicle thermal management system according to an exemplary embodiment of the present invention may further include a controller 60. The controller 60 may be a battery thermal management system (BMS) or an air conditioning controller, or it may be a separately configured controller.

[0065] The controller 60 can control the state of the thermostat 13 based on the temperature of the coolant flowing out of the range extender 12 and the temperature of the coolant flowing into the heater 15. Specifically, the controller 60 can control the angle of the valve core of the thermostat 13 based on the temperature of the coolant flowing out of the range extender 12 and the temperature of the coolant flowing into the heater 15, thereby changing the opening degree of the first outlet port ①, the second outlet port ②, and the third outlet port ③ of the thermostat 13. Here, an opening degree of 0% indicates that the outlet port is closed, and an opening degree of 100% indicates that the outlet port is fully open.

[0066] Furthermore, the controller 60 can control the operation of the three-way valve V and the second expansion valve EXV based on the temperature of the battery 22 and the temperature of the coolant flowing from the range extender 12. Specifically, the controller 60 can control the three-way valve V to allow the coolant flowing from the battery 22 to flow into the fourth coolant bypass line 25 and / or the heat exchanger 23, and control the second expansion valve EXV to allow the refrigerant flowing into the battery cooler 50 via the refrigerant branch line 45 to expand selectively.

[0067] In addition, the controller 60 can control the operation of the first pump 14, the second pump 17, the third pump 24 and the compressor 42.

[0068] Furthermore, the thermal management system of a vehicle according to an exemplary embodiment of the present invention may also include a cooling circuit for cooling a turbocharger, a cooling circuit for cooling electrical components (e.g., an electric motor), and so on. Descriptions of these circuits are omitted here to avoid unnecessarily obscuring the spirit of the invention.

[0069] Figure 3 To illustrate a schematic diagram of a vehicle thermal management system according to an exemplary embodiment of the present invention in a first mode, Figure 4 To illustrate a schematic diagram of a vehicle thermal management system according to an exemplary embodiment of the present invention in a second mode, Figure 5 This is a schematic diagram illustrating a vehicle thermal management system according to an exemplary embodiment of the present invention in a third mode. The following will be combined with... Figures 3 to 5 The first to third modes of the thermal management system of a vehicle according to an exemplary embodiment of the present invention will be described in detail.

[0070] like Figure 3 As shown, the first mode indicates that the heater 15 is used to heat the vehicle interior and the battery 22. In the first mode, the thermostat 13 is in a first state. In the first state, the controller 60 can control the first outlet port ① and the third outlet port ③ of the thermostat 13 to close, and the second outlet port ② to be fully open.

[0071] Furthermore, the controller 60 can control the operation of the second pump 17, allowing the coolant flowing from the second outlet port ② of the thermostat 13 to flow into the second coolant bypass line 32, and the coolant flowing from the second coolant bypass line 32 to flow into the second pump 17. Specifically, the coolant flowing into the thermostat 13 from the coolant outlet of the range extender 12 can all flow out from the second outlet port ② of the thermostat 13. The coolant flowing out from the second outlet port ② of the thermostat 13 can flow into the second coolant bypass line 32, and the coolant flowing through the second coolant bypass line 32 can flow into the first coolant line 11 upstream of the second pump 17, and then into the second pump 17. The coolant flowing out from the second pump 17 can flow back to the range extender 12. The coolant absorbs the heat generated by the operation of the range extender 12 and its temperature rises. Thus, as the coolant circulates along the loop formed by the second coolant bypass line 32 and a portion of the first coolant line 11, the temperature of the coolant gradually increases.

[0072] In the first mode, the heat generated by the range extender 12 is insufficient to heat the heating core 16 and the battery 22. Therefore, the controller 60 can control the heater 15 to operate to provide heating for the heating core 16 and the battery 22.

[0073] In addition, the controller 60 can control the operation of the first pump 14 so that the coolant flowing out of the heating core 16 flows into the first coolant bypass line 31, and the coolant flowing out of the first coolant bypass line 31 flows into the first pump 14.

[0074] Specifically, the coolant flowing from the first pump 14 flows along the first coolant line 11 through the heater 15 and the heating element 16. The coolant is heated as it flows through the heater 15, and the heated coolant heats the vehicle interior as it flows through the heating element 16. The coolant flowing from the heating element 16 flows into the first coolant bypass line 31, but does not flow into the first coolant line 11 upstream of the second pump 17.

[0075] Since the first outlet port ① and the third outlet port ③ of the thermostat 13 are closed and the second outlet port ② is fully open, the second coolant bypass line 32 and a portion of the first coolant line 11 can form an independent circuit, and the first coolant bypass line 31 and a portion of the first coolant line 11 can also form an independent circuit.

[0076] In addition, the controller 60 can control the operation of the third pump 24 so that the coolant in the second coolant circuit 20 can circulate along the second coolant line 21.

[0077] Specifically, the coolant flowing from battery 22 can flow along the second coolant line 21 through the three-way valve V and the heat exchanger 23. As the coolant in the second coolant line 21 flows through the heat exchanger 23, it can exchange heat with the coolant in the first coolant bypass line 31, thereby increasing the temperature of the coolant in the second coolant line 21. The heated coolant flowing from the heat exchanger 23 can then flow into the third pump 24 and the battery 22, thus heating the battery 22.

[0078] In the first mode, in the independent circuit formed by the second coolant bypass line 32 and a portion of the first coolant line 11, the coolant can absorb heat from the range extender 12 and its temperature rises. In the independent circuit formed by the first coolant bypass line 31 and a portion of the first coolant line 11, the coolant can be heated by the heater 15, thereby heating the vehicle interior through the heating element 16. In the second coolant circuit 20, the heat from the coolant heated by the heater 15 can be absorbed by the heat exchanger 23, thereby heating the battery 22.

[0079] like Figure 4As shown, the second mode utilizes the heat from the range extender 12 to heat the vehicle interior and battery 22. In the second mode, the thermostat 13 is in a second state. In this second state, the controller 60 can control the first outlet port ① of the thermostat 13 to gradually open until it is fully open as the temperature of the coolant flowing from the range extender 12 increases, the second outlet port ② to be fully open, and the third outlet port ③ to be closed. A portion of the coolant flowing from the coolant outlet of the range extender 12 into the thermostat 13 can flow into the first coolant line 11 upstream of the first pump 14 via the first outlet port ① of the thermostat 13, and the remaining coolant can flow into the second coolant bypass line 32 via the second outlet port ② of the thermostat 13.

[0080] Furthermore, the controller 60 can control the operation of the first pump 14 and the second pump 17, so that the coolant flowing out from the first outlet port ① of the thermostat 13 can flow along the first coolant line 11 through the first pump 14, the heater 15 and the heating core 16, a portion of the coolant flowing out from the heating core 16 can flow into the first coolant bypass line 31, and the remaining portion of the coolant flowing out from the heating core 16 can flow into the second pump 17; and so that the coolant flowing out from the second outlet port ② of the thermostat 13 can flow into the second coolant bypass line 32, and the coolant flowing out from the second coolant bypass line 32 can flow into the second pump 17.

[0081] Specifically, a portion of the coolant flowing from the coolant outlet of the range extender 12 into the thermostat 13 can flow out from the first outlet port ① of the thermostat 13. The coolant flowing out from the first outlet port ① of the thermostat 13 can flow along the first coolant line 11 through the first pump 14, the heater 15, and the heating core 16. At this time, the heater 15 may not be operating. Although the heater 15 is not operating, due to the increased temperature of the range extender 12, the temperature of the coolant flowing out of the range extender 12 is sufficient for heating the heating core 16 and the battery 22. Therefore, the coolant can heat the vehicle interior as it flows through the heating core 16. A portion of the coolant flowing out from the heating core 16 can flow into the first coolant bypass line 31, and the remaining coolant flowing out from the heating core 16 can flow along the first coolant line 11 into the second pump 17.

[0082] Most of the coolant flowing out of the heating core 16 can flow into the first coolant bypass line 31. The coolant flowing out of the first coolant bypass line 31 can flow into the first coolant line 11 upstream of the first pump 14, and then into the first pump 14. A small portion of the coolant flowing out of the heating core 16 can continue to flow along the first coolant line 11 into the second pump 17. The coolant flowing out of the second pump 17 can flow back to the range extender 12.

[0083] Meanwhile, the remaining coolant flowing from the coolant outlet of the range extender 12 into the thermostat 13 can flow out from the second outlet port ② of the thermostat 13. The coolant flowing out from the second outlet port ② of the thermostat 13 can flow into the second coolant bypass line 32, and the coolant flowing through the second coolant bypass line 32 flows into the first coolant line 11 upstream of the second pump 17, and then into the second pump 17. The coolant flowing out from the second pump 17 can flow back to the range extender 12.

[0084] In addition, the controller 60 can operate the third pump 24 so that the coolant in the second coolant circuit 20 can circulate along the second coolant line 21.

[0085] Specifically, the coolant flowing from battery 22 can flow along the second coolant line 21 through the three-way valve V and the heat exchanger 23. As the coolant in the second coolant line 21 flows through the heat exchanger 23, it can exchange heat with the coolant in the first coolant bypass line 31, thereby increasing the temperature of the coolant in the second coolant line 21. The heated coolant flowing from the heat exchanger 23 can then flow into the third pump 24 and the battery 22, thus heating the battery 22.

[0086] In the second mode, in the circuit formed by the second coolant bypass line 32 and a portion of the first coolant line 11, the coolant can absorb heat from the range extender 12 and its temperature rises. In the circuit formed by the first coolant bypass line 31 and a portion of the first coolant line 11, the heat from the range extender 12 can be used to heat the vehicle interior via the heating core 16. In the second coolant circuit 20, the heat from the coolant heated by the range extender 12 can be absorbed by the heat exchanger 23, thereby heating the battery 22.

[0087] like Figure 5 As shown, the third mode utilizes the heat from the range extender 12 to heat the vehicle interior and battery 22, and to cool the range extender 12. In the third mode, the thermostat 13 is in a third state. In the third state, the controller 60 can control the first outlet port ① of the thermostat 13 to be fully open, the second outlet port ② to gradually close until it is completely closed as the temperature of the coolant flowing from the range extender 12 increases, and the third outlet port ③ to gradually open until it is completely open as the temperature of the coolant flowing from the range extender 12 increases. A portion of the coolant flowing into the thermostat 13 from the coolant outlet of the range extender 12 can flow into the first coolant bypass line 31 via the first outlet port ① of the thermostat 13, and the remaining coolant can flow into the third coolant bypass line 33 via the third outlet port ③ of the thermostat 13.

[0088] Furthermore, the controller 60 can control the first pump 14 to not operate and the second pump 17 to operate, so that a portion of the coolant flowing out from the first outlet port ① of the thermostat 13 can flow into the first coolant bypass line 31, and the remaining portion of the coolant flowing out from the first outlet port ① of the thermostat 13 can flow along the first coolant line 11 through the first pump 14, the heater 15 and the heating core 16, and the coolant flowing out from the first coolant bypass line 31 and the coolant flowing out from the heating core 16 can flow together along the first coolant line 11 into the second pump 17; and so that the coolant flowing out from the third outlet port ③ of the thermostat 13 can flow into the radiator 18 on the third coolant bypass line 33, and the coolant flowing out from the radiator 18 can flow into the second pump 17.

[0089] Specifically, a portion of the coolant flowing from the coolant outlet of the range extender 12 into the thermostat 13 can flow out from the first outlet port ① of the thermostat 13. Since the first pump 14 is not operating, a portion of the coolant flowing out from the first outlet port ① of the thermostat 13 can flow into the first coolant bypass line 31. The remaining coolant flowing out from the first outlet port ① of the thermostat 13 can continue to flow along the first coolant line 11 through the first pump 14, heater 15, and heating core 16. At this time, the heater 15 may not be operating. Although the heater 15 is not operating, the temperature of the coolant flowing out of the range extender 12 is sufficient for heating the heating core 16 and the battery 22. Therefore, the coolant can achieve heating of the vehicle interior as it flows through the heating core 16.

[0090] The coolant flowing from the first coolant bypass line 31 and the coolant flowing from the heating core 16 can merge at the second end of the first coolant bypass line 31, and then flow together into the first coolant line 11 upstream of the second pump 17, and then into the second pump 17. The coolant flowing out of the second pump 17 can flow back to the range extender 12.

[0091] Meanwhile, the remaining coolant flowing from the coolant outlet of the range extender 12 into the thermostat 13 can flow out from the third outlet port ③ of the thermostat 13. The coolant flowing out from the third outlet port ③ of the thermostat 13 can flow into the third coolant bypass line 33, and then into the radiator 18 on the third coolant bypass line 33. In the radiator 18, the high-temperature coolant flowing from the range extender 12 can be cooled through heat exchange with the outside air. The cooled coolant can flow back to the range extender 12 via the third coolant bypass line 33 and the first coolant line 11, thereby cooling the range extender 12. The coolant flowing through the third coolant bypass line 33 can flow into the first coolant line 11 upstream of the second pump 17, and then into the second pump 17. The coolant flowing out from the second pump 17 can flow back to the range extender 12.

[0092] In addition, the controller 60 can operate the third pump 24 so that the coolant in the second coolant circuit 20 can circulate along the second coolant line 21.

[0093] Specifically, the coolant flowing from battery 22 can flow along the second coolant line 21 through the three-way valve V and the heat exchanger 23. As the coolant in the second coolant line 21 flows through the heat exchanger 23, it can exchange heat with the coolant in the first coolant bypass line 31, thereby increasing the temperature of the coolant in the second coolant line 21. The heated coolant flowing from the heat exchanger 23 can then flow into the third pump 24 and the battery 22, thus heating the battery 22.

[0094] In the third mode, in the circuit formed by the third coolant bypass line 32 and a portion of the first coolant line 11, the coolant temperature can be reduced in the radiator 18 through heat exchange with the outside air, thereby cooling the range extender 12. In the circuit formed by the first coolant bypass line 31 and a portion of the first coolant line 11, the heat from the range extender 12 can be used to heat the vehicle interior via the heating core 16. In the second coolant circuit 20, the heat from the coolant heated by the range extender 12 can be absorbed by the heat exchanger 23, thereby heating the battery 22.

[0095] Furthermore, especially in the third mode where the temperature of the range extender 12 is higher, in order to prevent the temperature of the coolant heated by the heat of the range extender 12 in the second coolant circuit 20 from becoming too high (e.g., exceeding the optimal operating temperature range of the battery 22), the controller 60 can control the operation of the three-way valve V so that the coolant flowing out of the battery 22 flows at least partially into the fourth coolant bypass line 25, rather than flowing entirely into the heat exchanger 23.

[0096] Specifically, the controller 60 can control the three-way valve V to open or partially open the second port connected to the fourth coolant bypass line 25 and close or partially close the third port connected to the second coolant line 21 upstream of the heat exchanger 23, based on the temperature of the battery 22 and the temperature of the coolant flowing from the range extender 12.

[0097] Furthermore, when battery 22 requires cooling, the refrigerant in the air conditioning refrigerant circuit 40 can be used to cool battery 22. Controller 60 can control the operation of the three-way valve V and the second expansion valve EXV based on the temperature of battery 22.

[0098] Specifically, the controller 60 can control the three-way valve V to open the second port connected to the fourth coolant bypass line 25 and close the third port connected to the second coolant line 21 upstream of the heat exchanger 23. Furthermore, the controller 60 can control the second expansion valve EXV to expand the refrigerant flowing into the battery cooler 50 via the refrigerant branch line 45. Thus, the coolant flowing into the fourth coolant bypass line 25 via the three-way valve V can exchange heat with the expanded refrigerant flowing into the refrigerant branch line 45 in the battery cooler 50. The coolant can be cooled, and the cooled coolant can be used to cool the battery 22.

[0099] Figure 6 This is a schematic diagram illustrating how the opening degree of each outlet port of the thermostat in the thermal management system of a vehicle according to an exemplary embodiment of the present invention changes with the angle of the thermostat valve core.

[0100] exist Figure 6 In the diagram, the horizontal axis represents the angle of the valve core of the thermostat 13 (in degrees), and the vertical axis represents the opening degree of the first outlet port ①, the second outlet port ②, and the third outlet port ③ of the thermostat 13 (in %). The three curves represent the changes in the opening degree of the first outlet port ①, the second outlet port ②, and the third outlet port ③ as the angle of the valve core of the thermostat 13 changes, respectively. The solid line represents the curve of the first outlet port ①, the dashed line represents the curve of the second outlet port ②, and the dotted line represents the curve of the third outlet port ③.

[0101] like Figure 6 As shown, in interval A (i.e., in the range from approximately 210 degrees to approximately 275 degrees), thermostat 13 is in the first state, in which the first outlet port ① and the third outlet port ③ of thermostat 13 are closed, and the second outlet port ② is fully open.

[0102] In interval B (i.e., in the range from approximately 105 degrees to approximately 210 degrees), thermostat 13 is in the second state, in which the first outlet port ① of thermostat 13 gradually opens until it is fully open as the temperature of the coolant flowing out of the range extender 12 increases, the second outlet port ② is fully open, and the third outlet port ③ is closed.

[0103] In range C (i.e., in the range from approximately 5 degrees to approximately 105 degrees), thermostat 13 is in the third state, in which the first outlet port ① of thermostat 13 is fully open, the second outlet port ② gradually closes until it is fully closed as the temperature of the coolant flowing out of range extender 12 increases, and the third outlet port ③ gradually opens until it is fully open as the temperature of the coolant flowing out of range extender 12 increases.

[0104] The vehicle thermal management system according to an exemplary embodiment of the present invention is applicable to electric vehicles, especially range-extended electric vehicles, and is capable of using the heat from the range extender to heat the vehicle interior and battery by controlling the state of the thermostat provided on the range extender.

[0105] According to an exemplary embodiment of the present invention, the vehicle's thermal management system can cool the range extender by controlling the state of the thermostat installed on the range extender.

[0106] The vehicle thermal management system according to an exemplary embodiment of the present invention can use the refrigerant in the air conditioning refrigerant circuit to cool the battery.

[0107] The foregoing description of specific exemplary embodiments of the invention is for illustrative and descriptive purposes. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed, and it will be apparent that many modifications and variations can be made in light of the foregoing teachings. The exemplary embodiments were chosen and described to explain certain principles of the invention and its practical application, thereby enabling others skilled in the art to implement and utilize various exemplary embodiments of the invention, as well as their different alternatives and modifications. The scope of the invention is intended to be defined by the appended claims and their equivalents.

Claims

1. A thermal management system for a vehicle, comprising: The first coolant circuit includes a range extender, a thermostat, a first pump, a heater, a heating element, and a second pump connected via a first coolant line. and The second coolant circuit includes a battery, a heat exchanger, and a third pump connected via a second coolant line; The first coolant circuit further includes a first coolant bypass line, the first end of which is connected to a first coolant line between the thermostat and the first pump, and the second end of which is connected to a first coolant line between the heating element and the second pump. The heat exchanger is also located on the first coolant bypass line to exchange heat between the first coolant circuit and the second coolant circuit.

2. The vehicle thermal management system according to claim 1, wherein, The first coolant circuit further includes: The second coolant bypass line has its first end connected to the thermostat and its second end connected to the first coolant line upstream of the second pump. A third coolant bypass line, wherein a first end of the third coolant bypass line is connected to a thermostat, and a second end of the third coolant bypass line is connected to a first coolant line upstream of the second pump; and A radiator, which is installed on the third coolant bypass line, is used to cool the coolant flowing through the third coolant bypass line.

3. The vehicle thermal management system according to claim 2, wherein, The inlet port of the thermostat is connected to the coolant outlet of the range extender; the first outlet port of the thermostat is connected to the first coolant pipeline upstream of the first end of the first coolant bypass pipeline; the second outlet port of the thermostat is connected to the first end of the second coolant bypass pipeline; and the third outlet port of the thermostat is connected to the first end of the third coolant bypass pipeline.

4. The vehicle thermal management system according to claim 3, wherein, Further includes: An air conditioning refrigerant circuit includes a compressor, a condenser, a first expansion valve, and an evaporator connected by refrigerant lines; The air conditioning refrigerant circuit further includes a refrigerant branch line, the first end of which is connected to the refrigerant line between the condenser and the first expansion valve, and the second end of which is connected to the refrigerant line between the evaporator and the compressor.

5. The vehicle thermal management system according to claim 4, wherein, The second coolant circuit further includes: A three-way valve is installed on the second coolant line between the battery and the heat exchanger; and A fourth coolant bypass line, the first end of which is connected to the second coolant line via a three-way valve, and the second end of which is connected to the second coolant line between the heat exchanger and the third pump; The first port of the three-way valve is connected to the second coolant line downstream of the battery, the second port of the three-way valve is connected to the first end of the fourth coolant bypass line, and the third port of the three-way valve is connected to the second coolant line upstream of the heat exchanger.

6. The vehicle thermal management system according to claim 5, wherein, Further includes: The battery cooler is located on the fourth coolant bypass line and on the refrigerant branch line; and The second expansion valve is located upstream of the battery cooler on the refrigerant branch line.

7. The vehicle thermal management system according to claim 6, wherein, Further includes: The controller is configured to control the state of the thermostat based on the temperature of the coolant flowing out of the range extender and the temperature of the coolant flowing into the heater.

8. The vehicle thermal management system according to claim 7, wherein, When the thermostat is in the first state The thermostat's first and third outlet ports are closed, while the second outlet port is fully open. The first pump operates, causing the coolant flowing from the heating core to flow into the first coolant bypass line, and the coolant flowing from the first coolant bypass line to flow into the first pump; The second pump operates, causing the coolant flowing from the second outlet port of the thermostat to flow into the second coolant bypass line, and the coolant flowing from the second coolant bypass line to flow into the second pump; The third pump operates, causing the coolant in the second coolant circuit to circulate along the second coolant pipeline; The heater operates to heat the coolant in the first coolant circuit.

9. The vehicle thermal management system according to claim 7, wherein, When the thermostat is in the second state The first outlet port of the thermostat gradually opens until it is fully open as the temperature of the coolant flowing out of the range extender rises; the second outlet port is fully open; and the third outlet port is closed. The first pump and the second pump operate such that the coolant flowing out of the first outlet port of the thermostat flows along the first coolant line through the first pump, the heater and the heating core, a portion of the coolant flowing out of the heating core flows into the first coolant bypass line and the remaining portion of the coolant flowing out of the heating core flows into the second pump; and the coolant flowing out of the second outlet port of the thermostat flows into the second coolant bypass line and the coolant flowing out of the second coolant bypass line flows into the second pump; The third pump operates, causing the coolant in the second coolant circuit to circulate along the second coolant pipeline; The heater is not working.

10. The vehicle thermal management system according to claim 7, wherein, When the thermostat is in the third state The first outlet port of the thermostat is fully open, the second outlet port gradually closes until it is fully closed as the temperature of the coolant flowing out of the range extender increases, and the third outlet port gradually opens until it is fully open as the temperature of the coolant flowing out of the range extender increases. The first pump is not operating while the second pump is operating, causing a portion of the coolant flowing from the first outlet port of the thermostat to flow into the first coolant bypass line, and the remaining coolant flowing from the first outlet port of the thermostat to flow along the first coolant line through the first pump, heater, and heating core. The coolant flowing from the first coolant bypass line and the coolant flowing from the heating core flow together along the first coolant line into the second pump; and causing the coolant flowing from the third outlet port of the thermostat to flow into the radiator on the third coolant bypass line, and the coolant flowing from the radiator to flow into the second pump; The third pump operates, causing the coolant in the second coolant circuit to circulate along the second coolant pipeline; The heater is not working.

11. The vehicle thermal management system according to claim 7, wherein, The controller is configured as follows: Based on the temperature of the battery and the temperature of the coolant flowing out of the range extender, the operation of the three-way valve is controlled so that the coolant flowing out of the battery flows into the fourth coolant bypass line and / or heat exchanger. The operation of the second expansion valve is controlled according to the battery temperature, so that the refrigerant flowing into the battery cooler through the refrigerant branch line expands selectively.

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