Integrated Thermal Management for EV Battery and Cabin HVAC
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Solution Overview
Problem
Electric vehicles face inefficiencies in energy management due to separate cooling and heating systems for indoor HVAC and battery temperature control, leading to reduced traveling range, especially in extreme weather conditions, which is more severe than in internal combustion engine vehicles.
Innovation Solution
An integrated thermal management module is configured to replace the conventional coolant circuit and heat pump system, incorporating a battery line, refrigerant line, indoor cooling and heating lines, and valves to efficiently recover waste heat and manage temperature, reducing material cost and weight while maintaining optimal battery performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate cooling and heating systems are used for indoor HVAC and battery temperature control, then each system can be optimized independently, but the overall energy efficiency deteriorates and traveling range is reduced
Solution Approach 1:
The patent merges the indoor HVAC system and battery thermal management system into a single integrated system. The coolant circuit serves dual purposes: it provides cooling for the battery through dedicated cooling lines and radiators, and it provides heating for the cabin through the HVAC heating core. This integration allows waste heat from the battery or environment to be utilized for cabin heating, and battery cooling capacity to support cabin cooling, thereby improving overall energy efficiency while maintaining reliable temperature control for both functions.
2Adaptability or versatility
If separate cooling and heating systems are used for indoor HVAC and battery temperature control, then each system can operate independently, but the device complexity increases
Solution Approach 1:
The integrated thermal management system achieves multi-functionality through a universal coolant circuit that serves multiple purposes. The same coolant loop provides battery cooling, battery heating (via heat pump), and cabin HVAC cooling and heating. Valves and control mechanisms enable the system to selectively direct coolant flow to different components based on operational requirements, maintaining system versatility while reducing overall complexity by eliminating redundant separate systems.
3Power
If a high-capacity PTC heater is installed to solve winter heating problems, then heating performance is improved, but the weight and cost increase excessively
Solution Approach 1:
The system converts the harmful waste heat generated by the battery or ambient environment into a beneficial resource for cabin heating during winter. Instead of relying on high-power PTC heaters that consume significant energy and add weight, the heat pump and integrated coolant circuit capture and redirect available heat sources to warm the cabin. This approach provides sufficient heating power by efficiently utilizing otherwise wasted thermal energy, thereby avoiding the need for heavy and energy-intensive PTC heating elements.
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 integrated thermal management module enhances energy efficiency, reduces material and weight costs, and prevents the excessive reduction in traveling range, enabling longer-distance operation by effectively managing both indoor and battery temperatures in electric vehicles.
Implementation Method 1
an evaporator...battery cooling lines...connected to the evaporator such that the coolant, which has exchanged heat with the evaporator, flows to the high-voltage battery core
Implementation Method 2
a condenser...battery heating lines...connected to the condenser such that coolant, which has exchanged heat with the condenser, flows to the high-voltage battery core
Implementation Method 3
a refrigerant line having a compressor...the refrigerant line having refrigerant that flows in the refrigerant line
Data Source
AI summary
An HVAC system of a vehicle includes: a battery line configured to thermally interconnect a first radiator and a high-voltage battery core and provided with a first pump; a refrigerant line having a compressor, a condenser, and an evaporator; an indoor cooling line interconnecting an indoor HVAC cooling core and the evaporator and having a second pump; an indoor heating line thermally interconnecting an indoor HVAC heating core and a condenser and having a third pump; battery cooling lines branching from opposite side points of the high-voltage battery core in the battery line, respectively, and connected to the indoor cooling line; battery heating lines branching from the opposite side points of the high-voltage battery core in the battery line, respectively, and connected to the indoor heating line; and a first valve disposed at one of the opposite branching points in the battery line.