Independent Thermal Circuits for Battery-Safe Cabin Heating

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Solution Overview

Problem

Electric vehicles face challenges in heating passenger compartments without affecting battery cooling circuits, leading to increased manufacturing costs and reduced driving range.

Innovation Solution

A vehicle design that includes independent battery cooling, refrigeration, and heating circuits, allowing separate coolant flows and heat exchange between the refrigeration cycle and heating circuit, enabling effective heating and cooling without battery cooling circuit interference.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If the battery cooling circuit and the air conditioning circuit are connected, then thermal management efficiency is improved, but the battery operation status affects passenger compartment heating and cooling availability

Engineering Contradiction:

Improvethermal management efficiencyVSAvoidheating and cooling availability

Core Design Contradiction:

Loss of energyVSReliability

Solution Approach 1:

The patent divides the thermal management system into three independent circuits: battery cooling circuit, air conditioning cooling circuit, and heating circuit. Each circuit operates independently with its own coolant flow path, eliminating interference between battery temperature control and passenger compartment climate control while maintaining thermal management efficiency.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces a heat exchanger as an intermediary component that enables thermal energy transfer between the refrigeration cycle and heating circuit without direct coolant mixing. This allows the heating circuit to receive thermal energy from the refrigeration cycle independently of the battery cooling circuit, ensuring reliable heating/cooling availability.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Device complexity

If the battery cooling circuit and air conditioning circuit are connected, then system integration is improved, but manufacturing cost increases

Engineering Contradiction:

Improvesystem integrationVSAvoidmanufacturing cost

Core Design Contradiction:

Device complexityVSEase of manufacture

Solution Approach 1:

The patent segments the thermal management system into independent circuits that can be manufactured and assembled separately. The battery cooling circuit, air conditioning circuit, and heating circuit are designed as modular units with standardized interfaces, simplifying manufacturing processes and reducing overall system cost despite maintaining system integration.

Inventive Principle:

Principle #1Segmentation

3Temperature

If electric heater is provided in air conditioning circuit, then passenger compartment heating is enabled, but electric power consumption increases

Engineering Contradiction:

Improvepassenger compartment temperatureVSAvoidelectric power consumption

Core Design Contradiction:

TemperatureVSUse of energy by moving object

Solution Approach 1:

The patent utilizes waste heat from the refrigeration cycle's condenser as a heat source for the heating circuit. By capturing and redirecting this otherwise wasted thermal energy to heat the passenger compartment through the heating circuit and heater core, the system reduces electric power consumption while maintaining effective heating capability.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The refrigeration cycle serves multiple functions: it provides cooling for the passenger compartment through the evaporator and simultaneously provides heating through the condenser's waste heat recovery. This multi-functionality reduces the need for separate heating systems and lowers overall electric power consumption.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This design allows for efficient heating and cooling of the passenger compartment without affecting battery cooling, reducing electric power consumption, and maintaining the comfort of the vehicle while minimizing manufacturing costs.

Implementation Method 1

the condenser is configured to exchange heat between the second coolant flowing through the refrigeration cycle and the third coolant flowing through the heating circuit

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Implementation Method 2

a battery cooling circuit configured to allow a first coolant to flow and adjust a temperature of the battery

Methodology Applied

Scientific EffectCooling: Cooling

Data Source

PatentUS20250187391A1vehicle

Publication Date: 2025.06.12 HONDA MOTOR CO LTD

AI summary

A vehicle, including: a battery; a battery cooling circuit configured to allow a first coolant to flow and adjust a temperature of the battery; a refrigeration cycle for air conditioning including an electric compressor, a condenser, an outdoor heat exchanger, and an evaporator, and configured to allow a second coolant to flow; and a heating circuit including a heater core and configured to allow a third coolant to flow, in which the battery cooling circuit, the refrigeration cycle, and the heating circuit are configured to allow the first coolant, the second coolant, and the third coolant flow through respective circuits independently, and the condenser is configured to exchange heat between the second coolant flowing through the refrigeration cycle and the third coolant flowing through the heating circuit.