Integrated Chiller Heat Pump for EV Battery and Motor Cooling
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Solution Overview
Problem
The existing heat pump systems for electric and hybrid vehicles are complex, leading to increased size and weight due to separate cooling systems for batteries and motors, resulting in noise, vibration, and reduced ride comfort due to multiple valves and complicated pipe layouts.
Innovation Solution
A heat pump system that uses a single chiller for heat exchange between a coolant and refrigerant to adjust battery module temperature, utilizing waste heat from electrical components for internal heating, simplifying the system and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate cooling systems are used for batteries and motors, then cooling performance is improved, but system complexity and weight increase
Solution Approach 1:
The patent merges the battery cooling system and motor cooling system into a single integrated cooling apparatus. The cooling apparatus includes a single chiller that serves both the battery module and electrical components, with a coolant circulation system that can selectively direct coolant to different components. This integration reduces the number of separate cooling circuits, valves, and pipes while maintaining the ability to independently control cooling for each component, thereby reducing system complexity and weight without compromising cooling performance.
Solution Approach 2:
The chiller is designed as a universal cooling device that can simultaneously or separately cool the battery module and electrical components. The coolant circulation system includes multiple pathways and control valves that enable the single chiller to perform multiple cooling functions. This multi-functionality allows the system to maintain optimal cooling performance for different components while using a unified cooling infrastructure, reducing overall system complexity.
2Measurement precision
If multiple valves and complicated pipe layouts are used, then cooling control precision is improved, but noise and vibration increase
Solution Approach 1:
The patent consolidates multiple valve functions into a reduced number of valves within the integrated cooling apparatus. The pipe layout is simplified by merging separate cooling circuits into a unified system with selective pathways. This reduction in the number of moving parts (valves) and connection points (pipes) directly decreases the sources of noise and vibration while maintaining the control precision needed for selective cooling of different components.
3Reliability
If separate cooling systems are used, then component protection is improved, but vehicle weight increases
Solution Approach 1:
The patent integrates the battery cooling system and motor cooling system into a single cooling apparatus, eliminating redundant components such as duplicate chillers, pumps, and pipe networks. This integration significantly reduces the overall weight of the cooling system while maintaining separate cooling pathways that allow independent control and optimal protection for each component. The unified system shares common infrastructure elements while preserving component-specific cooling capabilities.
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 reduces system complexity, enhances heating efficiency, optimizes battery performance, and increases travel distance by efficiently managing battery temperature, while also improving cooling performance and reducing power consumption.
Implementation Method 1
a chiller connected to a first connection line, which is connected to the battery coolant line between the second radiator and the battery module, and a second connection line connected to the first valve, and connected to a refrigerant line of an air conditioner through a refrigerant connection line, to adjust a temperature of the coolant by performing heat exchange between the coolant which is introduced in the chiller and a refrigerant which is selectively supplied from the refrigerant line of the air conditioner
Implementation Method 2
a condenser provided in the heating line between the second valve and the heater so that the coolant circulating through the heating apparatus passes therethrough and connected to the coolant line and the refrigerant line, and configured for circulating the coolant therein to perform heat exchange between the coolant and a refrigerant supplied through the refrigerant line
Implementation Method 3
an evaporator connected to the refrigerant line; a condenser provided in the heating line between the second valve and the heater so that the coolant circulating through the heating apparatus passes therethrough and connected to the coolant line and the refrigerant line, and configured for circulating the coolant therein to perform heat exchange between the coolant and a refrigerant supplied through the refrigerant line
Data Source
AI summary
A heat pump system for a vehicle may include a cooling apparatus of circulating a coolant in a coolant line to cool at least one electrical component provided in the coolant line; a battery cooling apparatus of circulating the coolant to the battery module; a chiller for heat exchanging the coolant with a refrigerant to control a temperature of the coolant; a heating apparatus that heats an interior of the vehicle using the coolant; and first, second, and third connection line.