Integrated EV Thermal Management via Heat Pump and Coolant Loop
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Solution Overview
Problem
Conventional electric vehicles require separate heating and cooling systems for the cabin interior and battery pack, leading to increased power consumption and reduced driving range due to inefficient thermal management.
Innovation Solution
A thermal management system that integrates the thermal regulation of the battery pack, electrical component module, and air-conditioning system using a heat pump unit, refrigerant-to-cooling water heat exchanger, and cooling water circulation, allowing for various thermal management modes by adjusting refrigerant and cooling water flow patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two independent heating and cooling systems are used (one for cabin interior and one for battery pack), then the battery pack can maintain its optimal operating thermal efficiently, but the overall power consumption of the electric vehicle increases significantly
Solution Approach 1:
The patent merges the cabin air conditioning system and battery pack thermal management system into a single integrated thermal management system. The heat pump unit serves dual purposes: conditioning cabin air through the evaporator and cooling the battery pack through the heat exchanger connected to the battery cooling circuit. This consolidation allows one system to perform multiple thermal management functions, reducing overall power consumption while maintaining effective battery temperature control.
Solution Approach 2:
The heat pump unit is designed with multi-functionality to serve both cabin air conditioning and battery thermal management. The compressor, condenser, and expansion valve components can operate in different configurations to provide cooling to either the cabin or the battery pack, or both simultaneously. This universal design enables the system to adapt to different thermal management needs without requiring separate dedicated systems.
2Reliability
If two separate heating and cooling systems are installed, then the battery pack thermal control can be maintained efficiently, but the manufacturing cost and weight of the thermal management system increase
Solution Approach 1:
The patent combines the cabin air conditioning system and battery pack thermal management system into a single integrated thermal management system. By merging these two separate systems into one, the total weight of the thermal management equipment is reduced. The shared components (compressor, condenser, expansion valve, refrigerant circulation system) eliminate the need for duplicate heavy equipment, while still providing effective thermal control for the battery pack.
3Reliability
If two separate heating and cooling systems are installed, then the battery pack thermal control can be maintained efficiently, but the device complexity increases
Solution Approach 1:
The patent integrates the cabin air conditioning system and battery pack thermal management system into a unified thermal management architecture. The heat pump unit with its compressor, condenser, expansion valve, and refrigerant circulation system serves both functions. The control system manages different operating modes (cabin cooling only, battery cooling only, or both simultaneously) through a single integrated controller, reducing the complexity that would arise from coordinating two independent systems.
4Weight of stationary object
If an integrated thermal management system is used, then manufacturing costs and weight are reduced, but the system must handle diverse thermal management modes for different components
Solution Approach 1:
The heat pump unit is designed with universal multi-functionality to handle diverse thermal management modes. The system can operate in different configurations: cooling the cabin through the evaporator, cooling the battery pack through the heat exchanger, heating the cabin using the condenser as a heat source, or any combination thereof. The control system automatically selects the appropriate operating mode based on real-time thermal requirements of the cabin and battery pack, providing the necessary flexibility despite the reduced system weight.
Solution Approach 2:
The integrated thermal management system employs dynamic operation where the heat pump unit can switch between different operating modes and configurations based on real-time conditions. The expansion valve and refrigerant flow paths can be dynamically adjusted to direct refrigerant to different components as needed. This dynamic adaptability allows the lighter integrated system to provide the same thermal management versatility as heavier separate systems.
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 integration reduces manufacturing costs and weight, enhances thermal regulation performance, and optimizes energy efficiency by eliminating the need for separate systems, while providing flexible thermal management modes tailored to driving conditions and environments.
Implementation Method 1
a heat pump unit configured to release and absorb heat based on the heat dissipation and condensation heat of a refrigerant
Implementation Method 2
a heat pump unit configured to release and absorb heat based on the heat dissipation and condensation heat of a refrigerant
Implementation Method 3
a refrigerant-to-cooling water heat exchanger having one side thermally connected to the heat pump unit to be cooled or heated by the refrigerant of the heat pump unit
Data Source
AI summary
A thermal management system for an electric vehicle includes a heat pump unit in which heat is released and absorbed due to the heat dissipation and condensation heat of the refrigerant; a refrigerant-coolant heat exchanger having one side thermally connected to the heat pump unit such that it is cooled or heated by the refrigerant of the heat pump unit; and a thermal management unit thermally connected to the other side of the refrigerant-coolant heat exchanger and configured to regulate the thermal of at least one of a battery pack and an electrical component module by using a coolant that has been cooled or heated by the refrigerant-coolant heat exchanger.