Integrated heat pump units and thermal management systems

Abstract

This utility model belongs to the field of thermal management technology, and relates to an integrated heat pump unit and thermal management system, including a compressor, a first three-way electronic valve, a water-cooled condenser, an electronic expansion valve, and a battery cooler. The compressor housing has multiple interfaces and cavities for installing and connecting the above components and forming a refrigerant flow path. This integrated heat pump unit, through an innovative design of the cavity and flow channel in the compressor housing, highly integrates the liquid storage and refrigerant flow functions into the compressor body. This significantly reduces the number of liquid storage tanks, external pipes, and joints required in traditional heat pump systems, not only reducing the refrigerant charge but also effectively reducing potential leakage points, thereby directly improving the system's sealing and reliability. Simultaneously, the integrated design reduces intermediate links in refrigerant flow, helping to reduce flow resistance and heat loss along the way, which is of positive significance for improving system energy efficiency.

Description

Technical Field

[0001] This utility model belongs to the field of thermal management technology and relates to an integrated heat pump unit and thermal management system. Background Technology

[0002] With increasing global environmental awareness and the deepening implementation of the Montreal Protocol on Substances that Deplete the Ozone Layer, China has officially released the National Program for Substances that Deplete the Ozone Layer (2025-2030), which explicitly requires that, starting from July 1, 2029, the air conditioning systems of newly registered M1 category vehicles (passenger vehicles with a capacity of no more than 9 passengers) be prohibited from using the traditional refrigerant R134a. This policy adjustment stems from the high global warming potential (GWP) of R134a. As a hydrofluorocarbon (HFC), it makes a significant contribution to global warming and no longer meets the stringent international requirements for greenhouse gas emission reduction.

[0003] Against this backdrop, alternative technologies for automotive air conditioning refrigerants have become a key focus of industry research and development. Among them, non-fluorinated alternative technologies such as R290 (propane) and R744 (carbon dioxide) have attracted much attention due to their outstanding environmental performance. R290, with its extremely low GWP (approximately 0.4% of R134a), excellent high-temperature cooling performance, and wide temperature range adaptability, exhibits significant advantages in thermodynamic properties, making it one of the most promising alternatives. However, R290 belongs to the A3 category of flammable substances (flammable and explosive), with an explosive concentration range of 2.1% to 9.5% (volume fraction). It poses a risk of combustion and explosion in confined or poorly ventilated environments, a characteristic that limits its direct application. Traditional electric vehicle thermal management systems, due to design inertia, generally employ complex structures with multiple components, pipelines, and connectors, and the refrigerant must directly enter the passenger compartment to achieve its cooling function. If the system architecture is directly adopted and R290 refrigerant is used, three major problems will be faced: First, the complex structure of the system leads to a large refrigerant charge, which significantly increases the risk of combustion and explosion; second, the large number of pipes and joints increases the probability of leakage many times over; third, the design of the refrigerant entering the passenger compartment directly means that once a leak occurs, flammable gas may directly spread into the compartment, posing a serious threat to the safety of the occupants.

[0004] Therefore, developing a new type of heat pump unit and electric vehicle thermal management system that combines low charge quantity, low leakage risk, and safety protection functions, based on the characteristics of R290 refrigerant, has become a key technical requirement for resolving the contradiction between environmental regulations and safety risks. Utility Model Content

[0005] In view of this, the purpose of this utility model is to provide an integrated heat pump unit and thermal management system for the application of R290 refrigerant, taking into account the characteristics of R290 refrigerant.

[0006] To achieve the above objectives, this utility model provides the following technical solution:

[0007] An integrated heat pump unit includes a compressor, a first three-way electronic valve, a water-cooled condenser, an electronic expansion valve, and a battery cooler. The compressor housing is provided with multiple interfaces and cavities for installing and connecting the above components and forming a refrigerant flow path.

[0008] The compressor's exhaust port is connected to port A of the first three-way electronic valve via a first interface on the compressor housing, and port B of the first three-way electronic valve is connected to a second interface on the compressor housing. The first interface is also connected to the refrigerant inlet of the water-cooled condenser.

[0009] The C port of the first three-way electronic valve is connected to the low-pressure cavity on the compressor housing, and the low-pressure cavity is also connected to the outlet of the battery cooler and the suction port of the compressor.

[0010] The outlet of the water-cooled condenser is connected to the high-pressure cavity on the compressor housing through the third interface on the compressor housing, and the high-pressure cavity is also connected to the inlet of the electronic expansion valve. The outlet of the electronic expansion valve is connected to the inlet of the battery cooler through the fifth interface on the compressor housing.

[0011] The compressor housing is also provided with a ninth interface that communicates with the low-pressure cavity, and refrigerant is added through the ninth interface.

[0012] Furthermore, it also includes an R290 concentration sensor, which is installed on the compressor housing and is used to detect R290 refrigerant leakage.

[0013] Furthermore, it also includes a foamed layer covering the outside of the component, the foamed layer having sound insulation, heat insulation, flow guiding and buffering functions.

[0014] Furthermore, it also includes a metal casing, which covers the outside of the foam layer to protect the internal unit; the bottom of the metal casing is equipped with an exhaust fan and a protective cover. When the R290 concentration sensor detects a leak, the exhaust fan is activated to mix the outside air with the leaked R290 and then discharge it.

[0015] Furthermore, the metal casing is provided with an electrical connector, and the control lines of all electrical components in the unit are connected inside the electrical connector.

[0016] Furthermore, the electronic expansion valve is mounted on the compressor housing via a fourth interface on the compressor housing;

[0017] The outlet of the battery cooler is connected to the low-pressure cavity through a sixth interface on the compressor housing.

[0018] Furthermore, it also includes a first pressure and temperature sensor and a second pressure and temperature sensor. The first pressure and temperature sensor is installed on the compressor housing through a seventh interface on the compressor housing, and the seventh interface is connected to the first interface and located between the compressor's exhaust port and the first interface.

[0019] The second pressure and temperature sensor is mounted on the compressor housing via an eighth interface on the compressor housing, and the eighth interface is connected to the low-pressure cavity.

[0020] Furthermore, the interface also includes a tenth interface, an eleventh interface, and a twelfth interface, wherein the tenth interface is connected to the high-pressure cavity, and the eleventh and twelfth interfaces are connected to the low-pressure cavity.

[0021] It also includes a second three-way electronic valve and a large-diameter electronic expansion valve; the second three-way electronic valve is installed on the twelfth interface, the A port of the second three-way electronic valve is connected to the low-pressure cavity, the B port is connected to the battery cooler outlet, and the C port is connected to the C port of the first three-way electronic valve and the A port of the heat pump condenser; the B port of the heat pump condenser is connected to the tenth interface, and the large-diameter electronic expansion valve is installed between the B port and the tenth interface of the heat pump condenser.

[0022] Furthermore, the compressor housing is a square column, and the high-pressure cavity and low-pressure cavity inside are used for the storage and circulation of refrigerant.

[0023] A thermal management system comprising the integrated heat pump unit described above.

[0024] An electric vehicle comprising the aforementioned thermal management system.

[0025] A residential triple heating management system includes the aforementioned integrated heat pump unit for providing cooling, heating, and hot water supply.

[0026] The beneficial effects of this utility model are as follows:

[0027] 1. This integrated heat pump unit utilizes an innovative design of the compressor housing's cavity and flow channels to highly integrate the liquid storage and refrigerant flow functions into the compressor body. This significantly reduces the number of liquid storage tanks, external pipes, and connectors required in traditional heat pump systems. It not only reduces the refrigerant charge but also effectively reduces potential leak points, thereby directly improving the system's sealing and reliability. This highly integrated design makes the unit structure more compact, achieving miniaturization and weight reduction, saving valuable space in the vehicle layout and improving space utilization. Simultaneously, the integrated design reduces intermediate steps in refrigerant flow, helping to reduce flow resistance and heat loss along the way, which is beneficial for improving system energy efficiency.

[0028] 2. In terms of safety protection, the unit adopts a multi-layered safety design. The metal casing provides robust physical protection for internal functional components, reducing the risk of damage and leakage due to impact. The foam layer filling the space between the casing and internal components not only provides excellent sound insulation and noise reduction, improving the user experience, but also effectively insulates heat, reducing heat loss and indirectly improving energy efficiency. More importantly, this foam layer also acts as a buffer and shock absorber in the event of impact or vibration, working in conjunction with the metal casing to protect core components. For potential leaks of flammable refrigerants (such as R290), the unit is equipped with an R290 concentration sensor and a forced ventilation system. Once a leak is detected, the system immediately closes the relevant valves to block the leak source and simultaneously activates the exhaust fan to draw in outside air to dilute the leaked refrigerant concentration, keeping it below the lower flammability limit, greatly improving safety. Furthermore, all electrical wiring harness connectors are located outside the unit casing, avoiding the risk of explosion caused by sparks from internal connector insertion and removal.

[0029] 3. This integrated heat pump unit demonstrates excellent applicability and flexibility. It can not only adapt to fully indirect heat exchange management systems (where the refrigerant exchanges heat indirectly with the passenger compartment, battery, etc., via the coolant circuit), but also, by introducing components such as a second three-way electronic valve, a large-diameter electronic expansion valve, and a heat pump condenser, can construct a semi-indirect heat exchange management system (where the refrigerant directly exchanges heat with ambient air, simplifying the coolant circuit and improving energy efficiency), thus broadening its application scenarios. Regarding refrigerant selection, the unit supports not only the environmentally friendly but flammable R290 refrigerant, but also mixed environmentally friendly refrigerants such as R454C and R474a. This design can flexibly address short-term transitional needs during the replacement of automotive refrigerants and provides conditions for solving potential temperature slip issues in different refrigerant systems, demonstrating its adaptability to future regulations and technological developments.

[0030] Other advantages, objectives, and features of this invention will be set forth in part in the description which follows, and in part will be apparent to those skilled in the art from the following examination and study, or may be learned from practice of this invention. The objectives and other advantages of this invention can be realized and obtained through the following description. Attached Figure Description

[0031] To make the objectives, technical solutions, and advantages of this utility model clearer, the preferred embodiments of this utility model will be described in detail below with reference to the accompanying drawings, wherein:

[0032] Figure 1 This is a schematic diagram of the casing structure of a compressor in an integrated heat pump unit according to an embodiment;

[0033] Figure 2This is a cross-sectional view of the housing cavity and flow channel of a compressor in an integrated heat pump unit according to an embodiment;

[0034] Figure 3 This is an exploded view of the interior of an integrated heat pump unit as described in the embodiment.

[0035] Figure 4 This is an exploded view of the casing of an integrated heat pump unit in one embodiment;

[0036] Figure 5 This is a schematic diagram of the external appearance of an integrated heat pump unit in the embodiment;

[0037] Figure 6 This is a schematic diagram of the structure of a thermal management system in Example 1;

[0038] Figure 7 This is a schematic diagram of the structure of a thermal management system in Example 2;

[0039] Figure 8 This is a schematic diagram of a thermal management system in Example 3.

[0040] Figure reference numerals: 1-Compressor; 2-First three-way electronic valve; 3-Water-cooled condenser; 4-Electronic expansion valve; 5-Battery cooler; 6-First pressure and temperature sensor; 7-Second pressure and temperature sensor; 8-R290 concentration sensor; 9-Foam layer; 10-Metal casing; 10A-Electrical connector; 11-Exhaust fan and cover; 12-Second three-way electronic valve; 13-Large-diameter electronic expansion valve; 14-Heat pump type condenser;

[0041] 1A - First Interface; 1B - Second Interface; 1C - Third Interface; 1D - High-Pressure Cavity; 1E - Fourth Interface; 1F - Fifth Interface; 1G - Sixth Interface; 1H - Low-Pressure Cavity; 1I - Seventh Interface; 1J - Eighth Interface; 1K - Ninth Interface; 1L - Tenth Interface; 1M - Eleventh Interface; 1N - Twelfth Interface; 1O - Thirteenth Interface;

[0042] 101-First electronic water pump; 102-First three-way proportional valve; 103-Cold air core; 104-First kettle; 105-Second electronic water pump; 106-Second three-way proportional valve; 107-Warm air core; 108-Second kettle; 109-Two-way regulating valve; 110-Third electronic water pump; 111-Battery; 112-One-way valve; 113-Nine-way valve; 114-Radiator; 115-Electric drive; 116-Electric fan; 117-Blower;

[0043] 209 - Four-way directional valve; 213 - Fourth electronic water pump;

[0044] 302 - First water tank; 303 - Air conditioning terminal equipment; 304 - First manifold; 307 - Heating terminal equipment; 308 - Second water tank; 309 - Second manifold; 310 - Water heater. Detailed Implementation

[0045] The following specific examples illustrate the implementation of this utility model. Those skilled in the art can easily understand other advantages and effects of this utility model from the content disclosed in this specification. This utility model can also be implemented or applied through other different specific embodiments, and various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of this utility model. It should be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of this utility model. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0046] The accompanying drawings are for illustrative purposes only and are schematic diagrams, not actual pictures. They should not be construed as limiting the present invention. To better illustrate the embodiments of the present invention, some parts in the drawings may be omitted, enlarged, or reduced, and do not represent the actual product dimensions. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings.

[0047] In the accompanying drawings of this utility model, the same or similar reference numerals correspond to the same or similar components. In the description of this utility model, it should be understood that if terms such as "upper," "lower," "left," "right," "front," and "rear" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, they are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, the terms used to describe positional relationships in the drawings are only for illustrative purposes and should not be construed as limiting this utility model. For those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances.

[0048] The integrated heat pump unit provided by this utility model is based on an innovative design of the compressor housing, which highly integrates the dispersed components of a traditional heat pump system. Utilizing the internal cavity of the housing, it achieves liquid storage, gas-liquid separation, and flow channel functions, significantly reducing external piping and joints, thereby lowering the refrigerant charge and leakage risk. The unit is particularly suitable for the environmentally friendly refrigerant R290 and is equipped with multiple safety protection measures, making it suitable for various scenarios such as electric vehicle thermal management and residential triple-heating systems.

[0049] Example 1: Thermal Management System for Electric Vehicles with Fully Indirect Heat Exchange

[0050] This embodiment provides an integrated heat pump unit applied to a thermal management system for an electric vehicle with fully indirect heat exchange, as shown in the attached figure. Figures 1-6 As shown.

[0051] 1. System Composition

[0052] The thermal management system mainly includes the integrated heat pump unit and coolant circuit of this utility model.

[0053] Integrated heat pump unit: includes compressor 1, first three-way electronic valve 2, water-cooled condenser 3, electronic expansion valve 4, battery cooler 5, first pressure and temperature sensor 6, second pressure and temperature sensor 7, R290 concentration sensor 8, foam layer 9, metal casing 10, and exhaust fan and protective cover 11. Except for the exhaust fan and protective cover 11, all other components are integrated and connected through interfaces and cavities on the casing of compressor 1.

[0054] The exhaust port of the compressor 1 is connected to port A of the first three-way electronic valve 2 via the first interface 1A on the housing. The first pressure and temperature sensor 6 is installed via the seventh interface 1I to monitor the exhaust pressure and temperature.

[0055] The B port of the first three-way electronic valve 2 is connected to the refrigerant inlet of the water-cooled condenser 3 through the second interface 1B.

[0056] The refrigerant outlet of the water-cooled condenser 3 is connected to the high-pressure cavity 1D inside the compressor housing via the third interface 1C.

[0057] The high-pressure cavity (1D) is connected to the inlet of the electronic expansion valve 4. The electronic expansion valve 4 is mounted on the housing via the fourth interface 1E.

[0058] The outlet of the electronic expansion valve 4 is connected to the refrigerant inlet of the battery cooler 5 via the fifth interface 1F.

[0059] The refrigerant outlet of the battery cooler 5 is connected to the low-pressure cavity 1H inside the compressor housing via the sixth interface 1G.

[0060] The low-pressure cavity 1H is connected to port C of the first three-way electronic valve 2 and the suction port of the compressor 1. The second pressure and temperature sensor 7 is installed through the eighth interface 1J to monitor the pressure and temperature on the low-pressure side.

[0061] Refrigerant is added through the ninth port 1K, which is also connected to the low-pressure cavity 1H.

[0062] R290 concentration sensor 8 is located at the rear end of the compressor housing and is used to monitor for leaks.

[0063] The foam layer 9 covers the exterior of the above-mentioned functional components, serving as sound insulation, heat insulation, flow guidance, and buffering.

[0064] The metal casing 10 covers the outside of the foam layer 9, and the bottom is equipped with an exhaust fan and a protective cover 11. The casing is equipped with a main electrical socket 10A.

[0065] Specifically, the interfaces and cavities on the housing of compressor 1 are as follows:

[0066] First interface 1A: Located at the front of the top housing, used to install the first three-way electronic valve 2;

[0067] Second interface 1B: Located on the upper right of the left side of the housing, used to connect to the inlet of water-cooled condenser 3;

[0068] The third interface 1C is located on the lower right side of the left housing and is used to connect to the outlet of the water-cooled condenser 3.

[0069] High-pressure cavity 1D: Located inside the left side of the casing, used for the flow and storage of high-pressure refrigerant;

[0070] Fourth interface 1E: Located at the lower right of the front housing, used to install the electronic expansion valve 4;

[0071] Fifth Interface 1F: Located on the lower left of the right side of the housing, used to connect to the battery cooler 5 inlet;

[0072] The sixth interface 1G: located on the upper left of the right side of the housing, is used to connect to the battery cooler outlet 5;

[0073] The low-pressure cavity 1H is located inside the right-side shell and is used for the flow and storage of low-pressure refrigerant.

[0074] Seventh Interface 1I: Located in the upper part of the front housing, used to install the first pressure and temperature sensor 6;

[0075] Eighth Interface 1J: Located on the upper right side of the right housing, used to install the second pressure and temperature sensor 7;

[0076] Ninth Interface 1K: Located at the front of the top housing, used for installing the refrigerant charging head;

[0077] Tenth Interface 1L: Reserved, located on the lower left side of the front housing, and can be used to connect metal pipe fittings;

[0078] Eleventh Interface 1M: Reserved, located at the front of the top housing, can be used to connect metal pipe fittings;

[0079] Twelfth Interface 1N: Reserved, located on the upper right side of the front housing, which can be used to install electronic valves;

[0080] Thirteenth Interface 1O: Reserved, located on the upper left of the right side of the housing, which can be used to install machining plugs.

[0081] The compressor's discharge port is connected to port 2A of the first three-way electronic valve 2. The seventh interface 1I is located in the middle of the channel between the compressor's discharge port and port A of the first three-way electronic valve 2, and is connected to both the compressor's discharge port and port A of the first three-way electronic valve 2. Port B of the first three-way electronic valve is connected to the compressor housing's second interface 1B, and port C of the first three-way electronic valve 2 is connected to the low-pressure cavity 1H. The third interface 1C is connected to the high-pressure cavity 1D, which is connected to the inlet of the electronic expansion valve 4. The outlet of the electronic expansion valve 4 is connected to the fifth interface 1F. The sixth interface 1G, the eighth interface 1J, and the ninth interface 1K are all connected to the low-pressure cavity 1H.

[0082] In addition, the tenth interface 1L reserved on the compressor housing is connected to the high-pressure cavity 1D, and the eleventh interface 1M and the twelfth interface 1N are connected to the low-pressure cavity 1H.

[0083] The compressor housing features a square cylindrical design, efficiently utilizing the space outside the compressor's cylindrical body. This space is used for cavity and flow channel design, achieving liquid storage, gas-liquid separation, and refrigerant flow. This saves on the need for a liquid receiver tank, refrigerant piping, and some joints, resulting in a smaller refrigerant charge and lower leakage rate. It also facilitates product miniaturization and weight reduction, simplifying vehicle layout and improving overall vehicle space utilization. Furthermore, it reduces intermediate conversion steps, thus minimizing flow resistance and heat leakage along the flow path.

[0084] The integrated heat pump unit also includes an R290 concentration sensor 8, which is placed at the rear end of the compressor housing to detect R290 leakage; the integrated heat pump unit also includes a foam layer 9, which covers the exterior of the above-mentioned components 1 to 8, and the foam layer has the functions of sound insulation, heat insulation, air conduction and buffering.

[0085] It also includes a metal casing 10 to protect the refrigerant module and prevent it from being directly impacted and broken, causing leakage. The bottom of the unit casing is also equipped with an exhaust fan and its protective cover 11. Once the R290 concentration sensor 8 detects an R290 leak, the exhaust fan is immediately activated. Under negative pressure, outside air enters the leakage channel from the edge of the protective cover and mixes with the leaked R290 gas before being discharged outside the unit by the exhaust fan. This ensures a low R290 concentration at the unit's leakage port, reducing the risk of combustion and explosion. The unit casing is also equipped with a main electrical connector 10A. The electrical connector 10A connects to the control lines of all electrical components inside the unit, preventing the potential for sparks from plugging and unplugging connectors inside the unit.

[0086] Furthermore, the refrigerant in the integrated heat pump unit can be R290 (propane), or it can be a mixture of environmentally friendly refrigerants such as R454C and R474a.

[0087] Coolant circuit: includes high-temperature coolant circuit and low-temperature coolant circuit, which exchange heat with refrigerant circuit through water-cooled condenser 3 and battery cooler 5.

[0088] The high-temperature coolant circuit includes:

[0089] 1) The second electronic water pump 105, the coolant passage of the water-cooled condenser 3, the second three-way proportional valve 106, the heater core 107, and the second water tank 108 are connected in series to form the first high-temperature coolant circuit; (crew cabin heating circuit)

[0090] 2) The second electronic water pump 105, the coolant passage of the water-cooled condenser 3, the second three-way proportional valve 106, the 6-2 passage of the nine-way valve 113, the third electronic water pump 110, the battery 111, the 8-7 passage of the nine-way valve 113, and the second water tank 108 are connected in series to form the second high-temperature coolant circuit; (battery heating circuit)

[0091] 3) The second electronic water pump 105, the coolant passage of the water-cooled condenser 3, the second three-way proportional valve 106, the 6-9 channels of the nine-way valve 113, the radiator 114, the electric drive 115, the 1-7 channels of the nine-way valve 113, and the second water tank 108 are connected in series to form the third high-temperature coolant circuit; (air cooling circuit)

[0092] 4) The second electronic water pump 105, the coolant passage of the water-cooled condenser 3, the second three-way proportional valve 106, the two-way regulating valve 109, the cold air core 103, and the second water tank 108 are connected in series to form the fourth high-temperature coolant circuit; (crew compartment dehumidification mixing circuit)

[0093] The cryogenic coolant circuit includes:

[0094] 1) The first electronic water pump 101, the coolant channel of the battery cooler 5, the first three-way proportional valve 102, the cold air core 103, and the first water tank 104 are connected in series to form the first low-temperature coolant circuit; (crew cabin cooling circuit)

[0095] 2) The first electronic water pump 101, the coolant channel of the battery cooler 5, the first three-way proportional valve 102, the 4-2 channel of the nine-way valve 113, the third electronic water pump 110, the battery 111, the 8-3 channel of the nine-way valve 113, and the first water tank 104 are connected in series to form the second low-temperature coolant circuit; (battery cooling circuit)

[0096] 3) The first electronic water pump 101, the coolant passage of the battery cooler 5, the first three-way proportional valve 102, the 4-9 channels of the nine-way valve 113, the radiator 114, the electric drive 115, the 1-3 channels of the nine-way valve 113, and the first water tank 104 are connected in series to form the third low-temperature coolant circuit. (Heat absorption circuit to air)

[0097] The third electronic water pump 110, battery 111, and one-way valve 112 are connected in series to form a battery temperature equalization circuit.

[0098] The electric vehicle thermal management system also includes an electric fan 116 and a blower 117, which are used to increase airflow to the radiator 114 and the cooling core 103, respectively.

[0099] 2. Working principle and process

[0100] Taking the heating of the crew cabin in winter as an example, the working process is explained as follows:

[0101] Refrigerant Cycle: Ports A and B of the first three-way electronic valve 2 are connected. The high-temperature, high-pressure R290 gaseous refrigerant discharged from compressor 1 enters the water-cooled condenser 3 through the first three-way electronic valve 2, where it is condensed into a high-temperature, high-pressure liquid, releasing heat to the high-temperature coolant circuit. The liquid refrigerant flows into the high-pressure cavity 1D for temporary storage, and then passes through the electronic expansion valve 4 to become a low-temperature, low-pressure gas-liquid mixture, where the high-pressure cavity 1D acts as a liquid storage unit. This mixture enters the battery cooler 5 to absorb heat from the low-temperature coolant circuit and completely evaporates into a gaseous state. The gaseous refrigerant returns to compressor 1 through the low-pressure cavity 1H, completing the cycle.

[0102] In this way, the high-temperature coolant circuit absorbs heat from the refrigerant and its temperature rises, while the low-temperature coolant circuit releases heat to the refrigerant and its temperature drops. Different circuit combinations are achieved by adjusting the first three-way proportional valve 102 and the second three-way proportional valve 106 and switching the channels of the nine-way valve 113 to meet the cooling, heating or heat dissipation needs of the passenger compartment, battery and electric drive. For example, when the passenger compartment needs heating, the first high-temperature coolant circuit exchanges heat with the air in the heater core to raise the air temperature, and the third low-temperature coolant circuit exchanges heat with the ambient air outside the vehicle in the radiator 114 to absorb heat from the ambient air outside the vehicle. This achieves thermal coupling between the integrated heat pump unit and the coolant circuit to heat the passenger compartment. In addition, in extremely low temperature environments, the third low temperature coolant can no longer absorb heat from the outside environment, and the liquid refrigerant cannot evaporate in the battery cooler 5. The refrigerant entering the compressor housing cavity 1H is still liquid. At this time, the first three-way electronic valve 2A port and 2C port are also connected, and the high temperature and high pressure gaseous refrigerant directly enters the compressor housing cavity 1H and mixes with the liquid refrigerant to become a fully gaseous refrigerant, thereby realizing hot gas bypass for extremely low temperature heating.

[0103] Specifically as follows:

[0104] Coolant circulation:

[0105] High-temperature circuit: The high-temperature coolant that absorbs heat from the water-cooled condenser 3 flows into the warm air core 107 under the drive of the second electronic water pump 105 and is regulated by the second three-way proportional valve 106. It exchanges heat with the air delivered by the blower 117 to provide heating for the crew cabin.

[0106] Low-temperature circuit: The low-temperature coolant that has absorbed heat in the battery cooler 5 is driven by the first electronic water pump 101 and regulated by the first three-way proportional valve 102 to flow to the radiator 114, where it exchanges heat with the outside air enhanced by the electronic fan 116 and absorbs ambient heat.

[0107] Extremely low temperature operation: When the ambient temperature is extremely low, the refrigerant may not be able to evaporate completely in the battery cooler 5. At this time, the control system controls the A and C ports of the first three-way electronic valve 2 to also connect, and part of the high-temperature and high-pressure refrigerant is directly bypassed to the low-pressure cavity 1H to mix with the unevaporated liquid refrigerant, ensuring that it returns to the compressor in gaseous form and achieves reliable operation.

[0108] Safety features: R290 concentration sensor 8 monitors in real time. Upon detection of a leak, the first three-way electronic valve 2 and electronic expansion valve 4 are immediately shut off to block refrigerant flow. Simultaneously, the exhaust fan is activated to dilute and expel the leaked gas from the unit, significantly reducing the risk of combustion and explosion. All electrical wiring harnesses are uniformly connected to the outside via the 10A electrical connector on the casing, avoiding internal sparks from plugging and unplugging.

[0109] This embodiment, through highly integrated and fully indirect heat exchange design, greatly reduces the amount of R290 refrigerant required and the risk of leakage, and ensures the safe application of the system in electric vehicles through multiple safety measures.

[0110] Example 2: Semi-indirect heat exchange electric vehicle thermal management system

[0111] This embodiment provides a thermal management system for electric vehicles applied to semi-indirect heat exchange, as shown in the attached figure. Figure 7 As shown, based on Embodiment 1, it adds a second three-way electronic valve 12, a large-diameter electronic expansion valve 13, and a heat pump type condenser 14.

[0112] 1. System Composition

[0113] Integrated heat pump unit: It retains the core structure of embodiment 1 and utilizes the reserved interface on the compressor housing: the twelfth interface 1N is equipped with a second three-way electronic valve 12; the tenth interface 1L is connected to port B of the heat pump condenser 14 through an external pipeline, and a large-diameter electronic expansion valve 13 is installed on the pipeline.

[0114] Port A of the second three-way electronic valve 12 is connected to the low-pressure cavity 1H.

[0115] The B port of the second three-way electronic valve 12 is connected to the outlet of the battery cooler 5.

[0116] The C port of the second three-way electronic valve 12 is connected to the C port of the first three-way electronic valve 2 and the A port of the heat pump condenser 14.

[0117] The coolant circuit mainly includes:

[0118] 1) The second electronic water pump 105, the coolant passage of the water-cooled condenser 3, the second three-way proportional valve 106, the heater core 107, and the second water tank 10 are connected in series to form the first high-temperature coolant circuit; (crew cabin heating circuit)

[0119] 2) The second electronic water pump 105, the coolant passage of the water-cooled condenser 3, the second three-way proportional valve 106, the third electronic water pump 110, the battery 111, the four-way reversing valve 209, and the second water tank 108 are connected in series to form the second high-temperature coolant circuit; (battery heating circuit)

[0120] 3) The first electronic water pump 101, the coolant channel of the battery cooler 5, the first three-way proportional valve 102, the cold air core 103, and the first water tank 104 are connected in series to form the first low-temperature coolant circuit; (crew cabin cooling circuit)

[0121] 4) The first electronic water pump 101, the coolant channel of the battery cooler 5, the first three-way proportional valve 102, the third electronic water pump 110, the battery 111, the four-way reversing valve 209, and the first water tank 104 are connected in series to form the second low-temperature coolant circuit; (battery cooling circuit)

[0122] 5) The third electronic water pump 110, battery 111, four-way reversing valve 209, and one-way valve 112 are connected in series to form a battery temperature equalization circuit.

[0123] 6) The fourth electronic water pump 213, radiator 114, electric drive 115, and four-way reversing valve 209 are connected in series to form an electric drive heat dissipation circuit.

[0124] Similarly, the electric vehicle thermal management system also includes an electric fan 116 and a blower 117, which are used to increase airflow to the radiator 114 and the cooling core 103, respectively.

[0125] 2. Working principle and process

[0126] When the crew compartment or / and the battery requires heating, ports A and B of the first three-way electronic valve 2 are connected. The high-temperature, high-pressure gaseous refrigerant discharged from the compressor 1 enters the refrigerant channel of the water-cooled condenser 3 and is condensed into a high-temperature, high-pressure liquid. During this process, the heat of the refrigerant is transferred to the high-temperature coolant circuit. The high-temperature, high-pressure liquid refrigerant at the outlet of the water-cooled condenser 3 enters the high-pressure cavity 1D and is throttled by the large-diameter electronic expansion valve 13 into a low-temperature, low-pressure gas-liquid mixture. It then enters the refrigerant channel of the heat pump condenser 14 (which acts as an evaporator at this time) and evaporates into a gaseous state, absorbing heat from the environment. The first high-temperature coolant circuit exchanges heat with the air in the heater core to raise the air temperature and achieve crew compartment heating. The second high-temperature coolant circuit enters the battery cold plate to achieve battery heating.

[0127] When the crew compartment and battery require cooling, ports A and C of the first three-way electronic valve 2 are connected. The high-temperature, high-pressure gaseous refrigerant discharged from the compressor 1 enters the heat pump condenser 14 and is condensed into a high-temperature, high-pressure liquid. During this process, the heat of the refrigerant is dissipated into the environment. The high-temperature, high-pressure liquid refrigerant flowing out of the heat pump condenser 14 enters the high-pressure cavity 1D, and then flows through the large-diameter electronic expansion valve 13 (which is fully open at this time and only serves as a passage). It is then throttled by the first electronic expansion valve 4 into a low-temperature, low-pressure gas-liquid mixture. Subsequently, it enters the refrigerant channel of the battery cooler and evaporates into a gaseous state, absorbing the heat of the low-temperature coolant circuit. The evaporated gaseous refrigerant passes through ports C and A of the second three-way electronic valve 12 and the low-pressure cavity 1H before returning to the compressor to enter the next cycle.

[0128] The first cryogenic coolant circuit exchanges heat with the air in the cold air core to reduce the air temperature and achieve cooling of the passenger compartment, while the second cryogenic coolant circuit enters the battery cold plate to cool the battery.

[0129] Similarly, in extremely low temperature environments, the refrigerant can no longer absorb heat from the outside environment. The liquid refrigerant cannot evaporate in the heat pump condenser, and the refrigerant entering the low-pressure cavity 1H is still in liquid state. At this time, the A and C ports of the first three-way electronic valve 2 are also connected, and the high-temperature and high-pressure gaseous refrigerant directly enters the low-pressure cavity 1H and mixes with the liquid refrigerant to form a fully gaseous refrigerant, thereby achieving hot gas bypass for extremely low temperature heating.

[0130] This embodiment introduces a heat pump type condenser 14. Although the refrigerant charge will increase slightly, it allows the refrigerant to directly exchange heat with the ambient air outside the vehicle during cooling or heating. Compared with the refrigerant indirectly exchanging heat with the ambient air outside the vehicle through the coolant, this simplifies the coolant circuit, reduces the heat exchange thermal resistance, saves water pump power consumption, improves the energy efficiency of the heat pump unit, and provides a wider range of application flexibility for integrated heat pump units.

[0131] Example 1: Residential Tri-Heating Management System

[0132] This embodiment provides a three-tiered heating management system for household cooling, heating, and hot water supply, as shown in the attached diagram. Figure 8 As shown, this indicates that the integrated heat pump unit of this invention is not limited to automotive applications, but can be extended to other fields that require heat exchange through an intermediate medium.

[0133] • System Composition: An integrated heat pump unit (as described in Example 2) serves as the heat source and is connected to the first water tank 302, the second water tank 308, the air conditioning terminal equipment 303 (such as fan coil units), the heating terminal equipment 307 (such as radiators or underfloor heating coils), the water heater 310, the first manifold 304, the second manifold 309, and corresponding water pumps and valves to form a system.

[0134] Specifically, in this embodiment, the first electronic water pump 101, the coolant channel of the battery cooler 5, the first water tank 302, the first channel of the first water distributor 304, the air conditioning terminal device 303, and the second channel of the first water distributor 304 are connected in series to form a first low-temperature coolant circuit.

[0135] The second electronic water pump 105, the second water tank 308, the coolant channel of the water-cooled condenser 3, the second three-way proportional valve 106, and the water heater 310 are connected in series to form the first high-temperature coolant circuit.

[0136] The second electronic water pump 105, the second water tank 308, the coolant channel of the water-cooled condenser 3, the second three-way proportional valve 106, the first channel of the second manifold 309, the heating terminal equipment 307, and the second channel of the second manifold 309 are connected in series to form the second high-temperature coolant circuit.

[0137] Its working principle is as follows:

[0138] Summer: The integrated heat pump unit operates in cooling mode, and the generated cooling capacity is transferred to the air conditioning terminal equipment 303 (such as fan coil unit) through the coolant channel of the battery cooler to provide cooling for the room; at the same time, the waste heat generated by the unit operation can be transferred to the water heater 310 through the coolant channel of the water-cooled condenser 3 to heat domestic hot water.

[0139] In winter: When the unit operates in heating mode, the heat generated can be supplied to the heating terminal equipment 307 (floor heating or radiators) and water heater 310 simultaneously or on demand through the coolant passage of the water-cooled condenser 3, so as to achieve heating and hot water supply.

[0140] This household triple heating management system achieves intelligent allocation and management of heating and cooling according to demand through the adjustment of manifolds, valves, and control systems.

[0141] This embodiment demonstrates the application potential of integrated heat pump units in home energy centers, achieving "multi-functionality in one unit" and improving energy utilization efficiency.

[0142] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of this utility model and are not intended to limit it. Although this utility model has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solution of this utility model without departing from the spirit and scope of this technical solution, and all such modifications or substitutions should be covered within the scope of the claims of this utility model.

Claims

1. An integrated heat pump unit, characterized in that, It includes a compressor (1), a first three-way electronic valve (2), a water-cooled condenser (3), an electronic expansion valve (4), and a battery cooler (5). The housing of the compressor (1) is provided with multiple interfaces and cavities for installing and connecting the above components and forming a refrigerant flow path. The exhaust port of the compressor (1) is connected to the A port of the first three-way electronic valve (2) through the first interface (1A) on the compressor housing, the B port of the first three-way electronic valve (2) is connected to the second interface (1B) on the compressor housing, and the first interface (1B) is connected to the refrigerant inlet of the water-cooled condenser (3). The C port of the first three-way electronic valve (2) is connected to the low-pressure cavity (1H) on the compressor housing, and the low-pressure cavity (1H) is also connected to the outlet of the battery cooler (5) and the suction port of the compressor (1); The outlet of the water-cooled condenser (3) is connected to the high-pressure cavity (1D) on the compressor housing through the third interface (1C) on the compressor housing, and the high-pressure cavity (1D) is also connected to the inlet of the electronic expansion valve (4). The outlet of the electronic expansion valve (4) is connected to the inlet of the battery cooler (5) through the fifth interface (1F) on the compressor housing. The compressor housing is also provided with a ninth interface (1K) that communicates with the low-pressure cavity (1H), and refrigerant is added through the ninth interface (1K).

2. The integrated heat pump unit according to claim 1, characterized in that, It also includes an R290 concentration sensor (8), which is disposed on the housing of the compressor (1) and is used to detect R290 refrigerant leakage.

3. The integrated heat pump unit according to claim 1 or 2, characterized in that, It also includes a foamed foam layer (9) covering the outside of the component, the foamed foam layer (9) having sound insulation, heat insulation, flow guiding and buffering functions.

4. The integrated heat pump unit according to claim 3, characterized in that, It also includes a metal casing (10), which covers the outside of the foam layer (9) to protect the internal unit; the bottom of the metal casing (10) is provided with an exhaust fan and a protective cover (11). When the R290 concentration sensor (8) detects a leak, the exhaust fan is activated to mix the outside air with the leaked R290 and then discharge it.

5. The integrated heat pump unit according to claim 4, characterized in that, The metal casing (10) is provided with an electrical connector (10A), and the electrical connector (10A) is internally connected to the control lines of all electrical components in the unit.

6. The integrated heat pump unit according to claim 1, characterized in that, The electronic expansion valve (4) is mounted on the housing of the compressor (1) via a fourth interface (1E) on the compressor housing; The outlet of the battery cooler (5) is connected to the low-pressure cavity (1H) through the sixth interface (1G) on the compressor housing.

7. The integrated heat pump unit according to claim 1, characterized in that, It also includes a first pressure and temperature sensor (6) and a second pressure and temperature sensor (7). The first pressure and temperature sensor (6) is installed on the housing of the compressor (1) through a seventh interface (1I) on the compressor housing. The seventh interface (1I) is connected to the first interface (1A) and is located between the exhaust port of the compressor (1) and the first interface (1A). The second pressure and temperature sensor (7) is mounted on the housing of the compressor (1) through the eighth interface (1J) on the compressor housing, and the eighth interface (1J) is connected to the low-pressure cavity (1H).

8. The integrated heat pump unit according to claim 1, characterized in that, The interface also includes a tenth interface (1L), an eleventh interface (1M), and a twelfth interface (1N), wherein the tenth interface (1L) is connected to the high-pressure cavity (1D), and the eleventh interface (1M) and the twelfth interface (1N) are connected to the low-pressure cavity (1H); It also includes a second three-way electronic valve (12) and a large-diameter electronic expansion valve (13); the second three-way electronic valve (12) is installed on the twelfth port (1N), the A port of the second three-way electronic valve (12) is connected to the low-pressure cavity (1H), the B port is connected to the outlet of the battery cooler (5), and the C port is connected to the C port of the first three-way electronic valve (2) and the A port of the heat pump condenser (14); the B port of the heat pump condenser (14) is connected to the tenth port (1L), and the large-diameter electronic expansion valve (13) is installed between the B port and the tenth port (1L) of the heat pump condenser (14).

9. The integrated heat pump unit according to claim 1, characterized in that, The compressor (1) has a square column housing, and the high-pressure cavity (1D) and low-pressure cavity (1H) inside are used for the storage and circulation of refrigerant.

10. A thermal management system, characterized in that, It includes an integrated heat pump unit as described in any one of claims 1-9.

Images