Integrated thermal management module for vehicle
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Solution Overview
Problem
Electric vehicles face inefficiencies in thermal management, leading to reduced mileage and increased costs due to the need for separate cooling and heating systems for indoor air conditioning and battery temperature control, which results in excessive energy consumption and weight.
Innovation Solution
An integrated thermal management module that includes multiple pumps and valves to manage coolant flow between heat exchangers, radiators, and refrigerant lines, allowing for efficient heat exchange and compact configuration, replacing the function of a heat pump to enhance thermal management efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate cooling and heating systems are constructed for indoor air conditioning and battery temperature control, then the battery module can maintain optimal temperature environment, but energy consumption increases and mileage is reduced by 30% or more at cooling in summer and 40% or more at heating in winter
Solution Approach 1:
The patent merges the indoor air conditioning system and battery thermal management system into a single integrated thermal management system. The coolant circulation system serves both the indoor heating/cooling cores and the battery cooling plate, allowing heat exchange between these components and the coolant to achieve temperature control for both the cabin and battery simultaneously, thereby reducing energy consumption compared to separate systems
Solution Approach 2:
The coolant circulation system performs multiple functions: it provides heating to the indoor air conditioning system via the first heat exchanger, cooling via the second heat exchanger, and temperature control for the battery module via the battery cooling plate. This multi-functional design eliminates the need for separate dedicated systems, reducing overall energy consumption while maintaining reliable temperature control
2Reliability
If separate cooling and heating systems are constructed for indoor air conditioning and battery temperature control, then the battery module can maintain optimal temperature environment, but the system weight increases due to duplicate components
Solution Approach 1:
The patent combines multiple thermal management functions into a single integrated system with shared components. The coolant circulation system includes a single pump, radiators, and heat exchangers that serve both indoor air conditioning and battery temperature control, eliminating duplicate components and thereby reducing overall system weight
Solution Approach 2:
The integrated thermal management system uses universal components that perform multiple functions. The first and second heat exchangers, battery cooling plate, and coolant circulation system collectively provide heating, cooling, and temperature regulation for both the cabin and battery, replacing what would otherwise require separate dedicated systems and reducing total component weight
3Temperature
If high capacity PTC is provided to solve the heating problem in winter, then the battery can be heated effectively, but cost and weight increase excessively
Solution Approach 1:
The patent converts the waste heat generated by the indoor air conditioning system into a useful resource for heating the battery module in winter. The coolant that has been heated by the indoor air conditioning heating core is directed to the battery cooling plate to provide heating, thereby eliminating the need for high-capacity PTC heating devices and reducing both weight and cost
Solution Approach 2:
The integrated thermal management system enables the indoor air conditioning system to serve the battery heating needs. The coolant circulation system automatically redirects heated coolant from the indoor air conditioning heating core to the battery cooling plate when heating is required, allowing the system to self-regulate and eliminate the need for separate high-capacity heating devices
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 integrated module enables efficient thermal management by minimizing refrigerant lines, compactly forming the system for improved space utilization and increasing the vehicle's Distance to Empty, while reducing energy consumption and weight.
Implementation Method 1
a first heat exchanger of the indoor heating line heat-exchanged with a condenser of a refrigerant line
Implementation Method 2
a second heat exchanger heat-exchanged with an evaporator of a refrigerant line
Implementation Method 3
a first pump configured for flowing coolant of an indoor heating line
Data Source
AI summary
An integrated thermal management module may include a first pump for flowing coolant of an indoor heating line for connecting a first heat exchanger heat-exchanged with a condenser of a refrigerant line and an indoor air-conditioning heating core, a second pump for flowing coolant of an indoor cooling line for connecting a second heat exchanger heat-exchanged with an evaporator of a refrigerant line and an indoor air-conditioning cooling core, a fourth pump for flowing coolant of a battery line for connecting a high-voltage battery core and a third radiator, a first valve simultaneously connected to a second radiator line for connecting the first heat exchanger and a second radiator, the indoor heating line, and the battery line to change flow direction of the coolant, and a second valve simultaneously connected to the indoor cooling line and the battery line to change flow direction of the coolant.