EV Air Conditioning Heat Exchanger Layout for Compact Cooling
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Solution Overview
Problem
Conventional air conditioning systems for electric vehicles face challenges in efficiently managing heat due to the lack of a heat source, leading to reduced fuel efficiency and frequent charging needs, while also consuming excessive energy and increasing package size with conventional refrigerant circulation modules.
Innovation Solution
An air conditioning system that miniaturizes the refrigerant circulation module by implementing a heat pump and utilizing heat exchange between refrigerant and coolant, with multiple coolant lines and valves to control coolant flow for efficient temperature adjustment and heat management, enhancing cooling performance without increasing the cold core size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the size of the cold core is increased to improve cooling performance, then cooling efficiency is improved, but the entire package size increases
Solution Approach 1:
The system divides the cooling function into two separate heat exchangers (first air conditioning heat exchanger and second air conditioning heat exchanger) that work in parallel or series depending on the mode. This segmentation allows the system to achieve sufficient cooling capacity without requiring a single oversized cold core, thereby reducing overall package size while maintaining cooling efficiency.
Solution Approach 2:
The second air conditioning heat exchanger serves dual purposes: it functions as a cooling heat exchanger in cooling mode and as a heating heat exchanger in heating mode. This multi-functionality allows the system to eliminate the need for separate dedicated heating and cooling components, reducing the overall package size while maintaining both cooling and heating capabilities.
2Ease of operation
If conventional refrigerant circulation modules are used for indoor air conditioning, then cooling function is provided, but excessive electric energy is consumed and package size increases
Solution Approach 1:
The system merges the refrigerant circulation system with the coolant circulation system by integrating the evaporator and condenser of the refrigerant circuit with the first and second heat exchangers of the coolant circuit. This combination allows the air conditioning function to be achieved through heat exchange between refrigerant and coolant, eliminating the need for separate high-power electric refrigerant compression and reducing overall energy consumption.
Solution Approach 2:
The system utilizes the waste heat from the motor and power electronics to provide heating for the cabin, and uses the cold coolant from the battery thermal management system to provide cooling. This self-service approach recovers waste energy that would otherwise be lost, reducing the need for additional energy input while maintaining comfortable cabin temperature.
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
Improves indoor cooling performance, reduces energy consumption, and efficiently manages battery and electronic component temperatures, thereby extending the distance to empty (DTE) and enhancing overall energy efficiency without enlarging the system's package.
Implementation Method 1
a first heat exchanger heat-exchanged with the evaporator of the refrigerant circuit
Implementation Method 2
the second heat exchanger connected so that the coolant of the first coolant line flows by connecting a front end and a rear end of a second air conditioning heat exchanger to a front end and a rear end of the first air conditioning heat exchanger, and heat-exchanged with the condenser of the refrigerant circuit
Implementation Method 3
a first air conditioning heat exchanger configured to adjust a temperature of air conditioning air through the heat exchange of the coolant
Implementation Method 4
the second air conditioning heat exchanger configured to adjust a temperature of air conditioning air through the heat exchange of the coolant
Data Source
AI summary
An embodiment air conditioning system includes a refrigerant circuit including a compressor, a condenser, an expander, and an evaporator, a first coolant line including a first heat exchanger and a first air conditioning heat exchanger, a second coolant line including a second heat exchanger, connected so that a coolant of the first coolant line flows by connecting front and rear ends of a second air conditioning heat exchanger to front and rear ends of the first air conditioning heat exchanger, and a first valve selectively controlling a flow of the coolant of the first coolant line on the front end of the first air conditioning heat exchanger, and a controller controlling the first valve in a heating mode so that the coolant cooled through the first heat exchanger in the first coolant line flows to the first air conditioning heat exchanger and the second air conditioning heat exchanger.