Cold Accumulator for Electric Vehicle HVAC Cooling

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Solution Overview

Problem

Existing cooling systems for hybrid and electric vehicles lack sufficient cooling capacity for high-voltage components, especially when the engine is stationary and waste heat from the combustion engine heats up these components unfavorably, and they struggle with precise temperature control and peak cooling demands.

Innovation Solution

An air conditioning system with a chargeable cold accumulator and a separate cooling circuit system that uses a coolant distribution unit to manage cooling energy, allowing for efficient cooling of high-voltage components and vehicle interiors by storing and releasing cooling energy as needed, even when the engine is off, and providing peak cooling during driving.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If conventional outside air cooling is used for power electronics and traction battery, then the cooling system is simple and low-cost, but sufficient cooling capacity is not available when the vehicle is stationary and the air conditioning compressor is off

Engineering Contradiction:

Improvecooling system structureVSAvoidcooling capacity availability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent implements a cold storage unit that pre-cools the power electronics housing and traction battery before the vehicle becomes stationary or before peak heating occurs. This preliminary cooling action stores cold energy that can be discharged later when the air conditioning compressor is off, ensuring continuous cooling capacity without requiring the compressor to run constantly.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent introduces a cold storage unit as an intermediary between the air conditioning system and the thermal management needs of power electronics and traction battery. This intermediary component buffers thermal energy, allowing the system to decouple the compressor operation from the actual cooling demand, thereby maintaining cooling capacity during stationary operation.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If the air conditioning compressor runs continuously to provide cooling capacity, then sufficient cooling is available for high-voltage components, but energy consumption increases and the system cannot respond quickly to peak cooling demands

Engineering Contradiction:

Improvecooling capacity availabilityVSAvoidcompressor energy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The cold storage unit performs preliminary cooling of power electronics and traction battery during periods when cooling demand is lower, storing cold energy that can be rapidly discharged during peak demand periods. This allows the compressor to operate intermittently rather than continuously, reducing energy consumption while maintaining reliable cooling capacity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system dynamically adjusts compressor operation based on real-time thermal conditions and the state of charge of the cold storage unit. The control system optimizes compressor run cycles to recharge the cold storage unit when possible, creating a dynamic balance between energy consumption and cooling capacity availability.

Inventive Principle:

Principle #15Dynamics

3Measurement precision

If a separate cooling circuit system with cold storage unit is implemented, then precise temperature control and peak cooling capacity are achieved, but system complexity and initial cost increase

Engineering Contradiction:

Improvetemperature control precisionVSAvoidcooling system structure

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent segments the cooling system into distinct functional circuits: a first cooling circuit for power electronics with its own heat exchanger, and a second cooling circuit for traction battery. Each circuit can be independently controlled and optimized, allowing precise temperature control for each component while maintaining modular system architecture that manages complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cold storage unit serves multiple functions: it pre-cools power electronics housing, pre-cools traction battery, and provides peak cooling capacity during stationary operation. This multi-functionality reduces the need for separate dedicated cooling systems for each component, thereby managing overall system complexity while achieving precise temperature control.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Temperature

If waste heat from combustion engine is dissipated during stationary operation, then engine cooling is maintained, but high-voltage components experience unfavorable temperature conditions and overheating

Engineering Contradiction:

Improveengine temperature controlVSAvoidheat exposure to high-voltage components

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The patent implements physically separate cooling circuits for the combustion engine and for high-voltage components (power electronics and traction battery). This segmentation allows independent temperature control of each system, enabling the engine to dissipate waste heat during stationary operation without adversely affecting the thermal conditions of high-voltage components.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cold storage unit acts as a thermal buffer between the engine cooling system and the high-voltage component cooling system. During stationary operation, when the engine generates waste heat, the cold storage unit provides the necessary cooling capacity to high-voltage components, isolating them from the thermal environment created by engine operation.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Ensures consistent and effective cooling of high-voltage components and vehicle interiors, maintaining optimal temperatures and addressing the limitations of conventional cooling systems by providing sufficient cooling capacity in all operating states and peak conditions.

Implementation Method 1

an air conditioning system with a chargeable cold accumulator (13) and a separate cooling circuit system (3) that uses a coolant distribution unit (11) to manage cooling energy, allowing for efficient cooling of high-voltage components and vehicle interiors by storing and releasing cooling energy as needed

Methodology Applied

Scientific EffectThermal energy storage: Thermal Energy Storage

Implementation Method 2

a first cooling circuit of the cooling circuit system, forming a distribution cooling circuit, has at least one heat exchanger for cooling transfer, which can be coupled directly or indirectly to the at least one evaporator of the refrigerant circuit

Methodology Applied

Scientific EffectHeat transfer: Heat Exchanger