Centralized Vehicle Energy Module for Integrated Thermal Layout
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Solution Overview
Problem
In environmentally friendly vehicles like electric and hybrid vehicles, the existing cooling systems are complex, leading to increased size and weight, noise, and vibration due to separate battery cooling systems and heat pump systems, which complicate the layout and reduce ride comfort.
Innovation Solution
A centralized energy module that selectively heat-exchanges heat energy generated from refrigerant by using high-temperature or low-temperature coolant, simplifying the system layout and reducing noise and vibration through the use of high-performance R152-a or R744 refrigerant and modular design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate battery cooling system and heat pump system are used, then cooling function is provided, but system complexity increases and device size increases
Solution Approach 1:
The patent merges the battery cooling system and heat pump system into a single integrated centralized energy module. The battery cooling radiator and heat pump condenser are combined into one radiator structure, and the expansion valve and evaporator are integrated into one evaporator assembly. This consolidation maintains the cooling function while significantly reducing system complexity and the number of separate components.
Solution Approach 2:
The centralized energy module is designed to perform multiple functions simultaneously - it serves as both the battery cooling system and the heat pump system. The single radiator structure functions as both the condenser for refrigerant and the radiator for battery cooling, while the single evaporator serves both the heat pump evaporator and battery cooling evaporator roles, enabling one system to fulfill multiple cooling functions.
2Reliability
If separate battery cooling system and heat pump system are used, then cooling function is provided, but device weight increases
Solution Approach 1:
The patent merges the battery cooling system and heat pump system into a single integrated centralized energy module. The battery cooling radiator and heat pump condenser are combined into one radiator structure, and the expansion valve and evaporator are integrated into one evaporator assembly. This consolidation maintains the cooling function while significantly reducing system complexity and the number of separate components.
3Ease of operation
If multiple valves for connection with respective connection pipes are adopted, then system connection is achieved, but noise and vibration increase
Solution Approach 1:
The patent merges the battery cooling system and heat pump system into a single integrated centralized energy module. The battery cooling radiator and heat pump condenser are combined into one radiator structure, and the expansion valve and evaporator are integrated into one evaporator assembly. This consolidation maintains the cooling function while significantly reducing system complexity and the number of separate components.
4Reliability
If separate battery cooling system and heat pump system are used, then cooling function is provided, but layout complexity increases
Solution Approach 1:
The patent merges the battery cooling system and heat pump system into a single integrated centralized energy module. The battery cooling radiator and heat pump condenser are combined into one radiator structure, and the expansion valve and evaporator are integrated into one evaporator assembly. This consolidation maintains the cooling function while significantly reducing system complexity and the number of separate components.
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
The centralized energy module enhances operation efficiency, reduces manufacturing costs, and improves ride comfort by simplifying the system layout and reducing noise and vibration, while using high-performance refrigerants to control vehicle temperature effectively.
Implementation Method 1
a condenser mounted on the base plate at a location spaced apart from the compressor and heat-exchanges the compressed refrigerant supplied from the compressor with coolant which flows into the condenser to condense the refrigerant
Implementation Method 2
an evaporator mounted on the base plate at a location spaced apart from the condenser and evaporating the refrigerant supplied from an expansion valve integrally mounted through heat-exchange with the coolant which flows into the evaporator
Data Source
AI summary
A centralized energy (CE) module for a vehicle includes: a base plate; a compressor mounted on the base plate and compressing refrigerant; a condenser mounted on the base plate at a location spaced apart from the compressor and heat-exchanges the compressed refrigerant supplied from the compressor with a coolant which flows into the condenser to condense the refrigerant; an evaporator mounted on the base plate at a location spaced apart from the condenser and evaporating the refrigerant supplied from an expansion valve integrally mounted through heat-exchange with the coolant which flows into the evaporator and supplying the evaporated refrigerant to the compressor; and an accumulator connected with the evaporator through the expansion valve, and supplied only a gas refrigerant among the evaporated refrigerants to the compressor while passing through the evaporator.