Integrated EV HVAC Thermal Routing for Cabin and Battery Heating
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Solution Overview
Problem
Existing electric vehicle (EV) cabin and rechargeable energy storage systems (RESS) face challenges in maintaining optimal performance across varying temperature ranges, with current heating and cooling methods being inefficient and separate.
Innovation Solution
An integrated HVAC system with a refrigerant and coolant circuit, featuring a compressor, condensers, heat exchangers, and three-way valves, allows for selective thermal energy exchange and coolant flow direction to efficiently heat or cool the RESS and cabin based on ambient conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate cooling heater is used to heat the RESS when operating temperature is low, then the RESS can be heated to maintain performance, but the system complexity increases and energy efficiency decreases
Solution Approach 1:
The patent merges the heating function into the existing coolant circulation system by utilizing the heater core and three-way valve to redirect coolant flow to the RESS. This eliminates the need for a separate heating system, reducing complexity while maintaining the ability to heat the RESS when needed.
Solution Approach 2:
The coolant circulation system is designed to serve multiple functions: cooling the RESS during high-temperature operation, heating the RESS during low-temperature operation, and heating the cabin. The three-way valve enables the system to switch between different thermal management modes, making the system universal and adaptable to various operating conditions.
2Reliability
If separate heating and cooling systems are used for cabin and RESS, then each component can be optimized independently, but the overall energy efficiency decreases and system complexity increases
Solution Approach 1:
The patent combines the cabin heating and RESS thermal management into a single integrated coolant circulation system. The heater core and three-way valve work together to distribute coolant flow between the cabin heater and RESS based on thermal management needs, enabling efficient heat transfer and reducing overall energy consumption.
Solution Approach 2:
The system recovers waste heat from the coolant that has cooled the RESS and redirects it to heat the cabin or provide additional heating to the RESS when needed. This converts what would otherwise be wasted thermal energy into a useful resource, improving overall energy efficiency.
3Reliability
If the coolant flow is always directed through the RESS for heating, then the RESS can be maintained at optimal temperature, but the cabin heating capability is reduced
Solution Approach 1:
The three-way valve provides dynamic control over coolant flow distribution, allowing the system to adapt to different thermal management requirements. The valve can redirect coolant flow between the RESS and cabin heater based on real-time temperature conditions, ensuring both components receive appropriate thermal management while maintaining system versatility.
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 system effectively maintains RESS performance by adaptively heating or cooling, enhancing efficiency and reducing the need for separate heating systems, thus optimizing thermal management.
Implementation Method 1
The flow of refrigerant is heated via operation of the compressor
Implementation Method 2
The refrigerant circuit and the coolant circuit exchange thermal energy at the internal condenser
Implementation Method 3
a chiller heat exchanger... The refrigerant circuit and the coolant circuit exchange thermal energy at the internal condenser
Implementation Method 4
a heater core... One or more of the RESS and the heater core are heated via the flow of coolant
Data Source
AI summary
A heating, ventilation and air conditioning (HVAC) system for a vehicle having a rechargeable energy storage system includes a refrigerant circuit having a flow of refrigerant circulated therethrough. The refrigerant circuit includes a compressor, an internal condenser, and a chiller heat exchanger. A coolant circuit is fluidly connected to the refrigerant circuit and has a flow of coolant circulated therethrough. The coolant circuit includes the chiller heat exchanger, the internal condenser, a heater core, a rechargeable energy storage system (RESS), and a three-way coolant valve to selectably direct the flow of coolant through the RESS and/or along a bypass passage to bypass the RESS.