Vehicle Climate Circuit Bypass for Low-Temperature Cabin Heating
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Solution Overview
Problem
Climate control systems in electric vehicles face inefficiencies at low outside temperatures due to reduced heat transfer from external heat exchangers, which can freeze and block airflow, and the use of additional electric heaters reduces battery range and requires additional installation space with buffer tanks.
Innovation Solution
A climate control system with a refrigerant and coolant circuit thermally coupled, featuring a line system with bypass lines and an additional heat source integrated into the coolant circuit, allowing for efficient heating and thawing by bypassing the external heat exchanger, thus reducing energy consumption and increasing vehicle range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If an external heat exchanger is used to heat the coolant circuit at low outside temperatures, then energy from outside air can be utilized, but condensate freezing occurs and heat transfer efficiency is reduced
Solution Approach 1:
The patent introduces an intermediary heating element integrated into the coolant circuit that can activate when the external heat exchanger becomes ineffective due to freezing. This intermediary component mediates between the failing external heat exchanger and the heating requirement, ensuring continuous heating capability without relying solely on the external heat exchanger at low temperatures.
Solution Approach 2:
The system changes operational parameters by switching between different heating modes based on temperature conditions. At higher outside temperatures, the external heat exchanger operates normally. At low temperatures where freezing occurs, the system activates the integrated heating element, changing the heat source parameter to maintain heating efficiency despite the external environment being unsuitable.
2Temperature
If additional electric heaters are used to heat the vehicle cabin, then heating capability is maintained, but battery power is consumed and vehicle range is reduced
Solution Approach 1:
The patent merges the heating functions by integrating a heating element directly into the coolant circuit system. This allows the climate control system to utilize waste heat from the powertrain more effectively, combining the cooling and heating systems into a unified thermal management system that reduces reliance on separate electric heating elements and minimizes battery power consumption.
Solution Approach 2:
The coolant circuit is designed with multi-functionality, serving both cooling and heating purposes. The same coolant loop that removes heat from the powertrain during operation can be redirected to provide cabin heating, making the system universal and reducing the need for dedicated electric heating components that would consume battery power.
3Reliability
If a buffer tank is installed to provide heat during thawing mode, then de-icing can be bridged, but installation space is required and vehicle weight increases
Solution Approach 1:
The patent extracts the heating function from a separate buffer tank system and integrates it directly into the coolant circuit. By removing the need for a dedicated buffer tank and its associated piping, the system achieves the same thawing capability without the additional weight and installation space requirements of a separate thermal energy storage system.
Solution Approach 2:
The heating element is nested within the existing coolant circuit structure rather than being a separate external component. This nesting approach allows the thawing functionality to be embedded in the already-present coolant pathways, eliminating the need for additional buffer tanks and reducing overall system weight while maintaining the ability to provide heat during de-icing operations.
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 system achieves energy-efficient cabin heating and thawing by utilizing an additional heat source, especially at low temperatures, without the need for additional installation space, thereby enhancing the range and efficiency of electric vehicles.
Implementation Method 1
the refrigerant circuit and the coolant circuit are thermally coupled to each other, in particular in the region of the evaporator and in the region of the condenser
Implementation Method 2
an additional heat source, which can be used in particular when the outside air is insufficient as a heat source
Implementation Method 3
A heated coolant, for example, cooling water, can flow to the heating body via the coolant circuit. In this case, an airflow guided over the surface of the heating body is heated.
Data Source
AI summary
An air-conditioning system, in particular for a motor vehicle, having a refrigerant circuit, which has an evaporator and a condenser, and a coolant circuit, wherein the refrigerant circuit and the coolant circuit are thermally coupled to each other, in particular in the region of the evaporator and in the region of the condenser, wherein the coolant circuit has a line system having junctions, wherein a heating body, a cooling body, an outside heat exchanger, an additional heat source, a first bypass line, and a second bypass line are integrated into the line system, wherein the first bypass line bypasses the additional heat source from the cooling body to the outside heat exchanger, and/or the second bypass line bypasses the additional heat source from the heating body to the outside heat exchanger.