EV Waste Heat Utilization System for Cabin Heating

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Solution Overview

Problem

Electric vehicles face a reduction in range due to the need for an electrically operated heating device, which draws power from the battery, leaving none for the motor, as they lack waste heat from an internal combustion engine for heating the vehicle interior.

Innovation Solution

A waste heat utilization system that integrates the vehicle's cooling circuit with the air conditioning circuit to utilize waste heat from the battery and electric motor for heating the interior, or discharge it into the surroundings, using a heat pump principle with chillers and heat exchangers to manage heat transfer efficiently.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If an electrically operated heating device is used to heat the vehicle interior, then the vehicle interior temperature comfort is improved, but the electric energy available for driving the electric motor is reduced, which worsens the vehicle range

Engineering Contradiction:

Improvevehicle interior temperatureVSAvoidelectric energy for motor driving

Core Design Contradiction:

TemperatureVSUse of energy by moving object

Solution Approach 1:

The patent converts the waste heat generated by the battery and electric motor, which would otherwise be discharged into the surroundings, into a useful resource for heating the vehicle interior. The cooling circuit that removes heat from these components is integrated with the air conditioning circuit to transfer this waste heat to the passenger compartment, thereby eliminating the need for separate heating energy consumption.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Temperature

If waste heat from battery and electric motor is discharged into the surroundings, then the cooling function is achieved, but the potential heating source for the vehicle interior is lost

Engineering Contradiction:

Improvebattery and motor coolingVSAvoidwaste heat energy

Core Design Contradiction:

TemperatureVSLoss of energy

Solution Approach 1:

The patent merges the cooling circuit and air conditioning circuit into a single integrated waste heat utilization system. The cooling circuit removes heat from the battery and motor, while the air conditioning circuit simultaneously provides climate control for the passenger compartment. This integration allows waste heat to be transferred to the interior space rather than being wasted, achieving both cooling of components and heating of the cabin.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated system serves multiple functions: it cools the battery and electric motor, conditions the air in the passenger compartment, and recovers waste heat for interior heating. This multi-functional approach eliminates the need for separate systems and maximizes energy utilization efficiency.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If separate cooling circuit and air conditioning circuit are used, then the functions are clearly separated, but the system complexity and cost increase

Engineering Contradiction:

Improvefunctional separationVSAvoidnumber of heat exchangers and circuits

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines previously separate cooling and air conditioning circuits into one integrated system. The cooling circuit for the battery and motor is merged with the air conditioning circuit, allowing heat removed from the powertrain components to be utilized for climate control in the passenger compartment. This reduces the number of separate heat exchangers and system components needed.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated circuit performs multiple functions simultaneously: cooling the battery, cooling the motor, and conditioning the passenger compartment air. This multi-functional design eliminates redundant components and reduces overall system complexity while maintaining reliable thermal management for all components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 system maintains high temperature comfort in the vehicle with low electric energy consumption, allows the battery to act as a heat accumulator, and reduces the need for separate heat exchangers, resulting in cost savings and extended vehicle range.

Implementation Method 1

a compressor (22) for compressing the working medium (21)

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

a condenser (11) for condensing the working medium (21)

Methodology Applied

Scientific EffectCondensation: Condensation

Implementation Method 3

an evaporator (23) for evaporating the working medium (21)

Methodology Applied

Scientific EffectEvaporation: Evaporation