Flexible Heat Pump Circuit for EV Cabin and Battery Thermal Management
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Solution Overview
Problem
Electric vehicles lack an efficient thermal management system for heating and cooling the cabin, windows, and battery, which can impact vehicle range and efficiency, especially when the internal combustion engine is not operating.
Innovation Solution
A vapor compression refrigeration circuit with a flexible heat pump system using refrigerants like HFO-1234yf or blends, combined with a coolant circuit and heat exchange network, allows for simultaneous heating and cooling by adjusting refrigerant flow through various heat exchangers and bypass channels to optimize thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If electric heaters are used to provide heat in EVs, then heating capability is improved, but vehicle range is reduced due to high energy consumption from the battery
Solution Approach 1:
The patent converts waste heat from the motor and battery into useful heating energy for the cabin through the heat pump system. The heat exchanger captures thermal energy that would otherwise be discarded, transforming it into a beneficial resource for cabin heating, thereby reducing the need for high-voltage heaters and preserving vehicle range.
Solution Approach 2:
The thermal management system enables the vehicle to heat its own cabin using internally generated waste heat from the motor and battery. The heat pump system autonomously captures and redistributes this waste heat without requiring external energy input, making the system self-sufficient and reducing dependency on the high-voltage battery.
2Temperature
If a compressor mechanically driven by the internal combustion engine is used for air conditioning, then cooling capability is improved, but the system becomes inoperable when the engine is turned off
Solution Approach 1:
The patent replaces the mechanical compressor driven by the internal combustion engine with an electric compressor that operates independently. This electric compressor can be powered directly by the battery or by waste heat recovery systems, enabling air conditioning operation regardless of engine status and providing true operational independence.
Solution Approach 2:
The thermal management system is designed to perform multiple functions using a single integrated architecture. The heat pump system can provide both heating and cooling capabilities, and the compressor can be powered by multiple sources (battery, waste heat), making the system universally applicable across different operating conditions and engine states.
3Stability of the object's composition
If a rigid heat pump system is used, then structural stability is improved, but the system cannot adapt to varying thermal management requirements
Solution Approach 1:
The patent implements a dynamic thermal management system with variable geometry components that can adjust their configuration based on real-time thermal requirements. The expandable heat exchanger surfaces and adjustable flow control mechanisms allow the system to optimize heat transfer efficiency across different operating conditions while maintaining structural integrity through controlled deformation.
Solution Approach 2:
The heat pump system is divided into modular segments with independent control capabilities. Each module can be activated or deactivated based on specific thermal management needs, allowing the system to adapt to varying requirements while maintaining overall structural stability. The segmented design enables flexible configuration for different heating and cooling scenarios.
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 provides efficient heating and cooling with reduced impact on vehicle range, eliminates the need for high-voltage heaters, and improves COP and capacity across varying ambient conditions.
Implementation Method 1
a compressor for compressing said first refrigerant in the vapor state from a first pressure to a higher second pressure
Implementation Method 2
an inner condenser for selectively condensing during low temperature ambient conditions at least a portion of said first refrigerant vapor from said compressor by rejecting heat to said cabin
Implementation Method 3
an inner condenser for selectively condensing during low temperature ambient conditions at least a portion of said first refrigerant vapor from said compressor by rejecting heat to said cabin
Implementation Method 4
a vapor compression refrigeration circuit... comprising: a first refrigerant... a compressor for compressing said first refrigerant in the vapor state
Data Source
AI summary
A heat transfer system to alternatively and/or simultaneously provide heating and cooling in a mobile vehicle that includes an electrical power source requiring heating and/or cooling during charging and/or operation and that includes a cabin that requires heat input during low temperature ambient conditions.