Hybrid Vehicle Cooling Device With Integrated Heat Exchanger
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Solution Overview
Problem
Hybrid vehicles require multiple cooling circuits for the combustion engine, electrical components, and battery, leading to increased cost and space under the hood due to the need for multiple heat exchangers and independent cooling systems.
Innovation Solution
A single heat exchanger divided into three members for high, low, and very low temperature ranges, with communication devices such as double acting and thermostatic valves to direct the heat transfer fluid between circuits based on operating conditions, allowing sharing of components and reducing the number of radiators needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If three separate cooling circuits with three heat exchangers are used for combustion engine, electrical components, and battery, then each component can be cooled to its optimal temperature range, but the number of heat exchangers and device complexity increases
Solution Approach 1:
The patent merges three separate cooling circuits into a single integrated cooling circuit that serves the combustion engine, electrical components, and battery simultaneously. This is achieved by using one heat exchanger with three distinct members (high temperature member for engine, low temperature member for electrical components, and very low temperature member for battery) instead of three separate heat exchangers, thereby reducing device complexity while maintaining temperature optimization for each component.
Solution Approach 2:
The single heat exchanger is designed to perform multiple functions by serving three different cooling needs through its three members. The heat exchanger can simultaneously cool the combustion engine to around 80°C, electrical components to around 60°C, and the battery to around 40°C, making it a universal cooling solution that replaces three specialized heat exchangers.
2Temperature
If three separate cooling circuits with three heat exchangers are used, then each component can be cooled independently, but the space occupied under the hood increases
Solution Approach 1:
The patent combines three separate heat exchangers into a single heat exchanger unit with three members, significantly reducing the space occupied under the hood. The integrated design allows all three cooling functions to be performed within the footprint of one heat exchanger rather than three separate units.
Solution Approach 2:
The heat exchanger is designed with a nested structure where three cooling members are integrated within a single heat exchanger body. The high temperature member, low temperature member, and very low temperature member are arranged in a compact nested configuration, allowing independent temperature control for each component while minimizing the overall space required.
3Temperature
If three separate cooling circuits with three heat exchangers are used, then optimal cooling performance is achieved, but the cost of the cooling system increases
Solution Approach 1:
The patent merges three separate heat exchangers into a single integrated heat exchanger unit, reducing the total number of components that need to be manufactured, installed, and maintained. This consolidation reduces manufacturing costs while preserving the ability to independently control the temperature of each cooled component through the three distinct members.
4Temperature
If climate control cooling circuit is used for additional cooling, then cooling capacity increases, but energy consumption increases due to compressor operation
Solution Approach 1:
The integrated cooling circuit is designed to self-regulate and provide additional cooling capacity when needed without requiring the climate control compressor to operate. The system uses the thermal energy from the combustion engine cooling to provide supplementary cooling for the battery and electrical components, eliminating the need for additional energy-consuming compression cycles.
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 enables efficient thermal management with reduced energy consumption and space requirements by sharing heat exchanger components, optimizing cooling for different vehicle conditions without the need for additional radiators or motor-ventilator groups.
Implementation Method 1
The cooling of the different electrical components, the electrical energy storage device, and the combustion engine is ensured by a heat transfer fluid circulating through thermal heat exchangers
Data Source
AI summary
A device for cooling the heat engine, electrical components, and an electrical energy storage device including: a first circuit, a second circuit, and a third circuit for cooling each of the heat engine, the electrical components, and the electrical energy storage device, respectively; a heat exchange device separated into three members, including a high temperature member connected to the first circuit, a low temperature member connected to the second circuit, and a very low temperature member connected to the third circuit; an upstream valve connected between the first and the third circuit located upstream of the high temperature member of the heat exchanger in the first circuit; and, a downstream valve connected between the first circuit and the third circuit located downstream of the high temperature member of the heat exchanger in the first circuit, where the downstream valve is a thermostatic valve which is actuated as a function of the temperature of the heat transfer fluid in the first circuit and where the upstream valve is actuated as a function of flow of the heat transfer fluid in the first circuit.