Integrated Thermal Management Unit for EV Battery and Cabin
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Solution Overview
Problem
Electric vehicles require effective thermal management of battery packs to maintain optimal performance within a specific temperature range, while also aiming to reduce system complexity and weight for improved fuel efficiency and environmental sustainability.
Innovation Solution
A thermal management unit and system that integrates a compressor, evaporator, pump, heater, and blower within a housing, with airflow and refrigerant management systems, including valves and sensors, to provide cooling or heating to battery packs and the vehicle cabin, optimizing temperature control and reducing weight and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate HVAC systems are used for battery packs and vehicle cabin, then thermal management effectiveness is improved, but system complexity and weight increase
Solution Approach 1:
The patent combines the battery thermal management system and vehicle HVAC system into a single integrated thermal management unit. The compressor, condenser, evaporators, and control mechanisms are merged into one modular assembly that can simultaneously provide cooling to both battery packs and vehicle cabin, eliminating the need for separate systems while maintaining thermal management effectiveness for both functions
Solution Approach 2:
The integrated thermal management unit is designed to perform multiple functions: cooling battery packs, cooling vehicle cabin, and potentially heating functions. The system uses a single compressor and refrigerant circulation loop that can be directed to different evaporators based on control valve positioning, allowing one system to replace multiple dedicated systems
2Reliability
If separate HVAC systems are used for battery packs and vehicle cabin, then thermal management effectiveness is improved, but system weight increases
Solution Approach 1:
The patent combines the battery thermal management system and vehicle HVAC system into a single integrated thermal management unit. The compressor, condenser, evaporators, and control mechanisms are merged into one modular assembly that can simultaneously provide cooling to both battery packs and vehicle cabin, eliminating the need for separate systems while maintaining thermal management effectiveness for both functions
Solution Approach 2:
The integrated thermal management unit is designed to perform multiple functions: cooling battery packs, cooling vehicle cabin, and potentially heating functions. The system uses a single compressor and refrigerant circulation loop that can be directed to different evaporators based on control valve positioning, allowing one system to replace multiple dedicated systems
3Reliability
If traditional HVAC components are used, then thermal management capability is maintained, but fuel efficiency decreases
Solution Approach 1:
The patent combines the battery thermal management system and vehicle HVAC system into a single integrated thermal management unit. The compressor, condenser, evaporators, and control mechanisms are merged into one modular assembly that can simultaneously provide cooling to both battery packs and vehicle cabin, eliminating the need for separate systems while maintaining thermal management effectiveness for both functions
Solution Approach 2:
The integrated thermal management unit is designed to perform multiple functions: cooling battery packs, cooling vehicle cabin, and potentially heating functions. The system uses a single compressor and refrigerant circulation loop that can be directed to different evaporators based on control valve positioning, allowing one system to replace multiple dedicated 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
The system efficiently manages temperature for battery packs and vehicle cabins, maintaining optimal performance, reducing weight and complexity, and enhancing fuel efficiency and environmental sustainability by integrating HVAC components into a single, self-contained module.
Implementation Method 1
a compressor configured to compress refrigerant gas
Implementation Method 2
a condenser in fluid communication with the compressor and configured to condense the refrigerant
Implementation Method 3
a first evaporator disposed within the housing and in fluid communication with the expansion device, wherein a blower is configured to force air over the first evaporator
Implementation Method 4
a first radiator of a heating system... a blower, wherein the blower is configured to force air over the first evaporator and first radiator to cool or heat the air
Data Source
Figure 1
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AI summary
A thermal management unit for providing cooling or heating to regions of a vehicle. The thermal management unit comprises a housing (11) containing a compressor (13) and a first evaporator (12) of a refrigerant system; a pump (36), a heater (39) as first radiator of a heating system; and a blower (17). The blower is configured to force air over the first evaporator and first radiator to cool or heat the air. The housing comprises an airflow outlet (46) through which the cooled or heated air can exit the housing, and an airflow inlet (47) though which air can enter the housing to be recirculated by the blower. The housing comprises a first refrigerant outlet port (16) through which refrigerant compressed by the compressor can pass out of the housing, and a second refrigerant inlet port (31) through which refrigerant can return into the housing for the supply to the first evaporator (12).