Compact EV HVAC Thermal Packaging via Segmented Modules
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional heating, ventilation, and air conditioning systems are not suitable for electric vehicles due to size constraints in compact urban vehicles and safety concerns with high-voltage electric heaters, necessitating a compact and safe thermal management solution for maintaining passenger compartment comfort.
Innovation Solution
A thermal packaging system comprising a heat treatment module with an electric radiator and a motor-fan unit for aerothermal treatment of airflow, and a distribution module that secures the system on a separation wall, allowing airflow distribution to various zones without a heat exchanger in the distribution module, which reduces size and enhances safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional heating, ventilation, and air conditioning facility is installed in the vehicle cabin, then thermal management function is provided, but the device size becomes too large for compact urban vehicles
Solution Approach 1:
The HVAC facility is divided into two separate modules: a heat treatment module containing the electric radiator and a distribution module. This segmentation allows each module to be optimized independently and reduces the overall space requirement compared to a conventional integrated HVAC system.
Solution Approach 2:
The distribution module is mounted on the separation wall between the cockpit and motor compartment, utilizing vertical space and alternative mounting locations rather than traditional horizontal dashboard space. This dimensional repositioning reduces the footprint within the cabin.
2Reliability
If a high voltage electric heater is used for heating in an electric vehicle, then heating function is provided, but safety risks of electrocution increase
Solution Approach 1:
The electric radiator (high voltage component) is completely separated from the distribution module (low voltage component) and mounted in different locations. The heat treatment module containing the high voltage electric heater is positioned in the motor compartment, while the distribution module is mounted on the separation wall, physically removing the electrocution hazard from the passenger cabin.
Solution Approach 2:
The separation wall acts as an intermediary barrier between the high voltage heat treatment module and the passenger cabin. This physical separation provides inherent safety isolation, preventing direct access to high voltage components while still allowing thermal management functionality.
3Volume of moving object
If the dashboard size is reduced to maintain interior space in compact vehicles, then passenger space is increased, but conventional HVAC facilities cannot be positioned
Solution Approach 1:
The distribution module is relocated from the traditional dashboard position to the separation wall between the cockpit and motor compartment. This alternative positioning utilizes previously underutilized space and eliminates the conflict with reduced dashboard dimensions while maintaining HVAC functionality.
Solution Approach 2:
By separating the HVAC system into independently mountable modules, the distribution module can be installed on the separation wall rather than requiring dashboard integration, enabling flexible installation in compact vehicle configurations.
4Volume of moving object
If a compact thermal management system is implemented, then vehicle size is reduced, but temperature zone differentiation capability is compromised
Solution Approach 1:
The distribution module incorporates multiple independently controllable air outlets (upper zone outlet and lower zone outlet) that can deliver air at different temperatures. This local differentiation capability allows distinct temperature zones within the cabin while maintaining a compact overall system structure.
Solution Approach 2:
The distribution module is divided into separate air outlet zones (upper and lower) with independent control, enabling localized temperature management in different cabin regions without requiring a large distributed HVAC system.
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
Enables efficient airflow temperature management within the compact vehicle cabin, ensuring comfort by providing distinct temperature zones while minimizing size and safety risks, allowing for reduced dimensions and safe operation.
Implementation Method 1
The heating function is ensured, on an electric vehicle, by an electric radiator, including a high voltage electric heater
Implementation Method 2
at least one motor-fan unit, able to circulate the flow of air in the Thermal packaging installation
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to temperature control equipment (3) for a vehicle, in particular an electric vehicle, enabling an aerothermic adjustment of an airflow to be distributed in a passenger compartment (H) of the vehicle, including at least one heat treatment module (8), capable of heat-treating the airflow, and a distribution module (9), capable of distributing the airflow to the passenger compartment (H). The heat treatment module (8) comprises a single means (21) for heating the airflow to be distributed in the passenger compartment (H), which consists of an electric radiator (21).