EV Heat Pump Octovalve Layout for Flexible Thermal Routing
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Solution Overview
Problem
Electric vehicles face complexity and inefficiency in cooling and heating systems due to the use of separate components, which increases manufacturing complexity and power consumption.
Innovation Solution
An enhanced valve unit, referred to as the octovalve, with 8 ports oriented in the same direction, allowing for flexible connection configurations between vehicle components, enabling various cooling and heating modes through adjustable stemshell channels, reducing asymmetry and channel crossing issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate cooling and heating components are used in electric vehicles, then heating and cooling functions can be provided, but manufacturing complexity and power consumption increase substantially
Solution Approach 1:
The patent combines separate cooling and heating components into a single integrated heat pump system. The heat pump uses a refrigerant cycle to provide both cooling (via evaporator) and heating (via condenser) functions, eliminating the need for separate heating elements and reducing overall system complexity while maintaining manufacturing ease
Solution Approach 2:
The heat pump system performs multiple functions using a single system architecture. The same refrigerant loop provides both cooling and heating capabilities, and the system can operate in different modes (cooling mode, heating mode, defrost mode) depending on environmental conditions and vehicle requirements, reducing the need for multiple dedicated components
2Use of energy by moving object
If separate cooling and heating components are used, then heating and cooling functions are achieved, but power consumption increases substantially
Solution Approach 1:
The heat pump captures waste heat from the battery cooling process and redirects it to the cabin heating system. When the battery needs cooling, the heat extracted is not discarded but transferred to heat the passenger compartment, turning what would be wasted energy into a useful heating source and significantly reducing power consumption for climate control
Solution Approach 2:
The system recovers thermal energy that would otherwise be discarded. The heat pump captures heat from the battery coolant during cooling operations and recovers it for cabin heating during cold weather, maximizing energy utilization and minimizing power consumption while maintaining a relatively simple system architecture
3Device complexity
If traditional valve configurations are used, then component connections are established, but asymmetry and channel crossing issues increase complexity
Solution Approach 1:
The patent employs an asymmetric valve body design with ports strategically positioned to eliminate channel crossing issues. The valve features a non-symmetric internal passage configuration that allows all eight ports to be accessed without requiring coolant channels to cross each other, simplifying the valve internal geometry while maintaining full connection flexibility for various system configurations
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 octovalve simplifies manufacturing, reduces power consumption, and enhances cooling and heating efficiency by allowing different components to be connected in series or parallel configurations, improving heat transfer performance and reducing temperature gradients within batteries and drive units.
Implementation Method 1
The evaporator may be utilized to cool the battery
Implementation Method 2
an expansion device disposed within the stemshell and in fluidic communication with the evaporator, the expansion device causing a pressure drop across the evaporator
Implementation Method 3
The condenser may be utilized to heat the coolant
Implementation Method 4
the expansion device causing a pressure drop across the evaporator
Data Source
AI summary
Systems, apparatuses, and methods for an enhanced heat pump are provided. An example embodiment includes a housing, the housing having a particular number of connection ports, each connection port being connected to a component of the electric vehicle, and the connection ports being configured to pass fluid; and a stemshell positioned within the housing, the stemshell comprising a plurality of channels, wherein at least a portion of the channels are in fluidic connection with the connection ports, wherein the stemshell is configured to rotate within the housing, and wherein rotation causes adjustment of the connection ports correspond which correspond to the channels.