Refrigerant Circuit Control Using Dual Heat Sources for EV Heating

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Solution Overview

Problem

Current refrigerant circuits in air conditioning systems are inefficient in utilizing multiple heat sources, limiting their heating capacity and overall efficiency, particularly in vehicles, where this inefficiency affects the travel range of electric vehicles.

Innovation Solution

A method that operates a refrigerant circuit in three heat pump modes: a first mode using heat from a first heat source, a second mode using heat from a second heat source, and a combined mode using heat from both sources, allowing for adaptive heat transfer based on available heat and needed heat, with dedicated heat exchangers and a valve assembly to manage flow.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If heat is transferred from only one heat source to the refrigerant, then the system operation is simple, but the heating capacity and efficiency are limited

Engineering Contradiction:
Improveheating capacityVSAvoidsystem complexity
Core Design Contradiction:
ProductivityVSDevice complexity

Solution Approach 1:

The system dynamically switches between different heat pump modes (first heat pump mode using first heat source, second heat pump mode using second heat source, and combined heat pump mode using both) based on actual circumstances such as available heat from sources and heat demand, allowing the heating capacity to be adaptively adjusted while managing system complexity through controlled operational variability

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The refrigerant circuit is designed to perform multiple functions by being able to operate in three different heat pump modes, utilizing either the first heat source alone, the second heat source alone, or both heat sources in combination, making the system universally adaptable to different heating scenarios and maximizing heat utilization

Inventive Principle:
Principle #6Universality (Multi-functionality)

2Productivity

If multiple heat sources are used simultaneously, then the heating capacity increases, but the control complexity increases

Engineering Contradiction:
Improveheating capacityVSAvoidcontrol ease
Core Design Contradiction:
ProductivityVSEase of operation

Solution Approach 1:

The system employs dynamic control strategies that adjust the operational mode based on real-time conditions including the amount of heat available from each heat source and the heat demand requirements, simplifying control by automatically selecting appropriate modes rather than requiring manual intervention for complex multi-source coordination

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The control system utilizes feedback from sensors monitoring heat source temperatures and heat demand conditions to automatically determine the optimal heat pump mode, enabling intelligent decision-making that simplifies operation while maximizing the utilization of multiple heat sources for enhanced heating capacity

Inventive Principle:
Principle #23Feedback

3Use of energy by moving object

If heat from both heat sources is transferred to the refrigerant, then the efficiency is maximized, but the system complexity increases

Engineering Contradiction:
Improveenergy efficiencyVSAvoidsystem complexity
Core Design Contradiction:
Use of energy by moving objectVSDevice complexity

Solution Approach 1:

The refrigerant circuit incorporates a combined heat pump mode that enables simultaneous heat transfer from both the first heat source and the second heat source to the refrigerant, maximizing energy efficiency by utilizing all available heat resources, while the system's design allows this complex function to be integrated into the existing refrigerant circuit architecture

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system dynamically activates the combined heat pump mode only when actual circumstances favor it (sufficient heat availability from both sources and adequate heat demand), thereby achieving high energy efficiency when needed while avoiding unnecessary complexity in normal operating conditions through selective mode activation

Inventive Principle:
Principle #15Dynamics

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 approach enhances the refrigerant circuit's efficiency and heating capacity, reducing energy consumption and increasing the travel range of electric vehicles by effectively utilizing multiple heat sources, including ambient air and coolant from vehicle components.

Implementation Method 1

heat is transferred to the refrigerant from a first heat source in a first heat pump mode, and from a second heat source that is different from the first heat source in a second heat pump mode

Methodology Applied
Scientific EffectHeat transfer: Heat Exchanger

Implementation Method 2

Heat is transferred to the refrigerant from both the first heat source and the second heat source in a combined heat pump mode

Methodology Applied
Scientific EffectThermal energy transfer: Conduction (thermal)

Data Source

PatentUS20240377094A1Method for operating a refrigerant circuit
Publication Date: 2024.11.14 MAHLE INT GMBH
  • US20240377094A1 patent drawing
  • US20240377094A1 patent drawing
  • US20240377094A1 patent drawing

AI summary

The present disclosure relates to a method for operating a refrigerant circuit through which a refrigerant circulates, in which heat is transferred from a first heat source to the refrigerant in a first heat pump mode, and from a second heat source to the refrigerant in a second heat pump mode. Efficiency and heating capacity are increased therewith in that heat is transferred to the refrigerant simultaneously from both the first heat source and the second heat source in a combined heat pump mode. The disclosure also relates to an air conditioning system that contains a refrigerant circuit operated in this manner.