Integrated Thermal Management Module for Electric Vehicle Battery and HVAC
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Solution Overview
Problem
Electric vehicles face inefficiencies in thermal management, leading to reduced driving distances and increased costs due to the need for separate cooling and heating systems for indoor air conditioning and battery temperature control, which complicates the cooling and heating circuit and increases weight and cost.
Innovation Solution
A thermal management system integrating coolant and refrigerant components and lines into a compact module, featuring a battery line with a radiator and pump, an indoor heating line with a hydrothermal heater and valves, and a refrigerant line with a compressor and condenser, along with a chiller for heat exchange, to efficiently manage energy for both air conditioning and battery heating and cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate cooling and heating systems are built for indoor air conditioning and battery temperature control, then temperature control function is improved, but device complexity increases
Solution Approach 1:
The patent merges the indoor air conditioning system and battery thermal management system into a single integrated thermal management system. The coolant circulation system serves dual purposes: cooling the battery through dedicated battery cooling lines and providing heating/cooling for the vehicle interior through the air conditioning system. This consolidation reduces the number of independent circuits and components while maintaining comprehensive temperature control functionality.
Solution Approach 2:
The coolant circulation system is designed with multi-functionality to serve both battery thermal management and indoor air conditioning needs. The same coolant loops and heat exchangers are utilized for both applications, with control valves directing coolant flow to different destinations based on system requirements. This universal approach eliminates the need for separate dedicated systems.
2Adaptability or versatility
If separate cooling and heating systems are built for indoor air conditioning and battery temperature control, then temperature control function is improved, but weight increases
Solution Approach 1:
The patent combines multiple thermal management functions into a single integrated system, eliminating redundant components such as separate pumps, radiators, and control systems for battery cooling and air conditioning. By sharing common components like the coolant circulation system and heat exchangers, the overall system weight is reduced while maintaining full temperature control capability for both battery and interior.
3Adaptability or versatility
If separate cooling and heating systems are built for indoor air conditioning and battery temperature control, then temperature control function is improved, but cost increases
Solution Approach 1:
The integrated thermal management system consolidates multiple functions into a unified architecture, reducing the total number of components that need to be manufactured, assembled, and installed. This approach lowers manufacturing costs by eliminating redundant parts and simplifying the supply chain, while still providing comprehensive temperature control for both battery and interior environments.
4Ease of operation
If complicated coolant and refrigerant components and lines are mounted separately, then installation flexibility is improved, but installation complexity increases
Solution Approach 1:
The patent integrates coolant and refrigerant components into a unified modular assembly that can be installed as a single unit in the vehicle. This integration reduces the number of separate installation steps and connections required, while the modular design maintains flexibility for different vehicle platforms. The assembled unit includes pre-connected lines and components, simplifying the installation process.
5Ease of operation
If complicated coolant and refrigerant components and lines are mounted separately, then installation flexibility is improved, but system weight increases
Solution Approach 1:
The integrated modular assembly combines coolant and refrigerant components into a compact unit, eliminating the weight of separate mounting structures and reducing overall system mass. The shared components and integrated design reduce material usage while maintaining installation flexibility through standardized mounting interfaces.
6Ease of operation
If complicated coolant and refrigerant components and lines are mounted separately, then installation flexibility is improved, but cost increases
Solution Approach 1:
The modular integrated assembly reduces manufacturing cost by consolidating components into a single manufacturable unit, reducing assembly steps, and minimizing the number of separate parts that need to be sourced and managed. The standardized design enables economies of scale while maintaining installation flexibility through universal mounting interfaces.
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 integrated system enhances cooling and heating efficiency, reduces the resistance of coolant and refrigerant, and allows for compact installation, improving energy management and reducing weight and cost in electric vehicles.
Implementation Method 1
a chiller for heat exchange
Implementation Method 2
an indoor heating line with a hydrothermal heater
Data Source
AI summary
A thermal management system for a vehicle may include a battery line connected to a high-voltage battery core, provided with a first radiator, and through which coolant is communicated by a first pump; an indoor heating line connected to a heating core for indoor air conditioning, provided with a hydrothermal heater therein, provided with a second pump to fluidically-communicate the coolant, and provided with a first valve at a downstream point of the heating core; a first and a second battery heating line branched or joined at the downstream point of the heating core in the indoor heating line to be connected to the upstream point and the downstream point of the high-voltage battery core, respectively; and a refrigerant line provided with an expansion valve, a cooling core for indoor air conditioning, a compressor, and a condenser.