Integrated EV Thermal Management With Heat Pump Coolant Routing
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Solution Overview
Problem
Conventional electric vehicles face challenges in efficiently managing the temperature of battery packs and electric component modules due to heat generation and external temperature fluctuations, leading to increased power consumption and reduced driving range.
Innovation Solution
A unified thermal management system integrates a heat pump unit and temperature management unit, using coolant and refrigerant to manage temperatures of battery packs and electric component modules, allowing flexible flow patterns and various thermal management functions without separate heating and cooling systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two separate thermal management systems are provided (one for cabin air-conditioning and another for battery pack), then temperature control reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the cabin air-conditioning system and battery thermal management system into a single integrated thermal management system. The heat pump unit serves dual purposes: providing cabin heating/cooling and managing battery temperature. This consolidation reduces the number of separate systems while maintaining reliable temperature control for both functions through a unified coolant circulation architecture.
Solution Approach 2:
The heat pump unit and coolant circulation system are designed to perform multiple functions simultaneously. The same heat pump unit provides both cabin air-conditioning and battery thermal management. The coolant circulation system serves both the battery pack and heat exchangers, enabling a single system to handle diverse thermal management requirements without sacrificing reliability.
2Reliability
If two separate thermal management systems are provided (one for cabin air-conditioning and another for battery pack), then temperature control reliability is improved, but manufacturing cost increases
Solution Approach 1:
The patent consolidates two separate thermal management systems into one integrated system, reducing the total number of components that need to be manufactured and assembled. The unified heat pump unit and shared coolant circulation infrastructure lower manufacturing costs while maintaining the reliability needed for both cabin air-conditioning and battery temperature control.
3Reliability
If two separate thermal management systems are provided (one for cabin air-conditioning and another for battery pack), then temperature control reliability is improved, but vehicle weight increases
Solution Approach 1:
The patent integrates the cabin air-conditioning system and battery thermal management system into a single unified system. By sharing common components such as the heat pump unit, coolant circulation system, and heat exchangers, the overall system weight is reduced compared to having two completely separate systems, while still providing reliable temperature control for both functions.
4Reliability
If additional heating and cooling systems are added for battery pack, then temperature control reliability is improved, but energy consumption increases
Solution Approach 1:
The heat pump unit is designed to serve multiple thermal management functions simultaneously - cabin air-conditioning and battery temperature control. By using a single heat pump unit for both purposes rather than separate heating and cooling systems, the patent reduces overall energy consumption while maintaining the reliability needed for effective temperature management of the battery pack.
5Reliability
If additional heating and cooling systems are added for battery pack, then temperature control reliability is improved, but driving range decreases
Solution Approach 1:
The integrated thermal management system uses a single heat pump unit to provide both cabin air-conditioning and battery thermal management. This multi-functional approach reduces the total energy consumption compared to having separate dedicated systems, thereby preserving more energy for propulsion and extending the vehicle's driving range while maintaining reliable temperature control.
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 reduces manufacturing costs and weight, improves temperature control performance, and enhances energy efficiency by eliminating the need for additional heating and cooling systems, while supporting multiple thermal management modes.
Implementation Method 1
a refrigerant-coolant heat exchanger disposed beneath the heat pump unit and fluidly connected to both the heat pump unit and the temperature management unit
Data Source
AI summary
The thermal management system for an electric vehicle according to an embodiment of the present invention may provide a thermal management system for an electric vehicle, comprising: a thermal management unit; a heat pump unit coupled to a lower portion of the thermal management unit; and a refrigerant-coolant heat exchanger disposed below the heat pump unit and fluidly connected to the heat pump unit and the thermal management unit. Here, the thermal management unit may include: a valve housing in which a coolant circulation channel is formed and a plurality of connection ports are provided; a first coolant control valve disposed on one side of the valve housing; and a second coolant control valve disposed on the other side of the valve housing.