Heat Pump System With Gas Injection and Integrated Battery Chiller

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Solution Overview

Problem

Current heat pump systems for electric and hybrid vehicles are complex, leading to increased size, weight, and noise due to separate battery cooling systems, which compromise heating performance and efficiency, and result in higher electricity consumption.

Innovation Solution

A heat pump system utilizing a single chiller for heat exchange between refrigerant and coolant, combined with a gas injection device to selectively increase refrigerant flow rate, simplifying the system and optimizing battery module temperature control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a separate battery cooling system is provided, then battery temperature control is improved, but system complexity and weight increase

Engineering Contradiction:

Improvebattery temperature controlVSAvoidsystem complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent merges the battery cooling function with the existing heat pump system by integrating a battery cooling passage into the heat pump's coolant circulation system. The coolant flows through both the heat pump components and the battery cooling passage, allowing a single system to perform both heating/cooling of the vehicle cabin and temperature control of the battery, thereby reducing system complexity and weight while maintaining effective battery temperature control

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The heat pump system is designed to serve multiple functions: it provides heating and cooling for the vehicle cabin while simultaneously serving as a battery cooling system. The coolant circulation apparatus and radiator are used for both purposes, making the system universal and eliminating the need for separate dedicated battery cooling components

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Temperature

If a separate battery cooling system is provided, then battery temperature control is improved, but weight increases

Engineering Contradiction:

Improvebattery temperature controlVSAvoidsystem weight

Core Design Contradiction:

TemperatureVSWeight of moving object

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Temperature

If separate cooling systems are provided, then battery and motor cooling is improved, but layout complexity increases

Engineering Contradiction:

Improvecooling performanceVSAvoidlayout complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

4Adaptability or versatility

If multiple valves are used for connection pipes, then system functionality is improved, but noise and vibration increase

Engineering Contradiction:

Improvesystem functionalityVSAvoidnoise and vibration

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

5Temperature

If electric heater is used for heating, then heating function is provided, but electricity consumption increases

Engineering Contradiction:

Improveheating functionVSAvoidelectricity consumption

Core Design Contradiction:

TemperatureVSUse of energy by moving object

Solution Approach 1:

The patent utilizes the waste heat generated by the battery during operation and the heat from the radiator (which would otherwise be discarded) and redirects it through the heat pump system to provide heating for the vehicle cabin. This converts harmful waste heat into a useful resource, providing heating functionality while reducing electricity consumption compared to using an electric heater

Inventive Principle:

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

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 solution enhances cooling and heating performance, reduces system complexity and weight, and improves battery module efficiency, thereby increasing vehicle mileage and reducing manufacturing costs.

Implementation Method 1

a chiller (40) heat-exchanging a coolant selectively supplied from the coolant circulation apparatus (3) with a refrigerant supplied from the air conditioner (10)

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Implementation Method 2

a gas injection device (30) increasing a flow rate of a refrigerant circulating in the refrigerant line (11) by bypassing a part of the refrigerant passing through the internal condenser (12a) to a compressor (19)

Methodology Applied

Scientific EffectGas injection: Injector

Implementation Method 3

evaporation in the evaporator through the receiver dryer and the expansion valve

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 4

the air conditioner system condenses a gaseous coolant of a high temperature and a high pressure compressed by the compressor

Methodology Applied

Scientific EffectCondensation: Condensation

Data Source

PatentUS11571948B2Heat pump system for vehicle

Publication Date: 2023.02.07 HYUNDAI MOTOR CO LTD

AI summary

A heat pump system for a vehicle may control a temperature of a battery module by use of one chiller in which a refrigerant and a coolant are heat-exchanged; and may increase a flow rate of the refrigerant by applying a gas injection device that selectively operates in a cooling, heating, or dehumidifying mode of a vehicle, maximizing cooling and heating performance.