Integrated Thermal Management System
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Solution Overview
Problem
Electric vehicles face challenges in thermal management due to the need for separate energy sources for heating, leading to decreased fuel economy and inefficient cooling performance, as existing refrigerant circulation modules consume excessive energy and increase in size, making it difficult to maintain sufficient cooling efficiency.
Innovation Solution
An integrated thermal management system that miniaturizes the refrigerant circulation module by using a refrigerant circuit with multiple coolant lines and switching valves to facilitate heat exchange between refrigerant and coolant, allowing for efficient cooling and heating of interior air, batteries, and PE components without increasing the cold core size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cold core size is increased to ensure sufficient cooling efficiency, then cooling performance is improved, but the overall package size increases
Solution Approach 1:
The evaporator is nested within the cold core structure, with the refrigerant circulation module integrated inside the cold core. This allows the refrigerant circuit to be housed within the existing cold core volume, improving cooling efficiency without increasing the overall package size.
Solution Approach 2:
The refrigerant circulation module and cold core are merged into a single integrated structure. The compressor, condenser, expander, and evaporator are combined with the cold core, eliminating the need for separate refrigerant circulation equipment and reducing overall package size while maintaining cooling efficiency.
2Reliability
If a refrigerant circulation module is used to cool the interior, then cooling performance is achieved, but electrical energy consumption increases and device size increases
Solution Approach 1:
The refrigerant circulation module serves multiple functions: it cools the interior through the evaporator and cold core, cools the battery through the third coolant line, and cools PE components through the fourth coolant line. This multi-functionality reduces the need for separate cooling systems, lowering overall electrical energy consumption while maintaining effective cooling performance.
Solution Approach 2:
The refrigerant circulation module is integrated with the battery cooling system and PE component cooling system through shared coolant lines. This merging of cooling functions into a single system reduces electrical energy consumption and device size compared to having separate cooling systems for each component.
3Adaptability or versatility
If separate cooling systems are used for interior, battery, and PE components, then each component's cooling needs are met, but device complexity and package size increase
Solution Approach 1:
The cooling system is segmented into multiple coolant lines with independent control: the first coolant line for interior cooling, the second coolant line for battery cooling, the third coolant line for PE component cooling, and the fourth coolant line for additional cooling needs. Switching valves control the flow distribution to meet specific cooling requirements while maintaining a relatively simple integrated structure.
Solution Approach 2:
A single refrigerant circulation module provides cooling for multiple components (interior, battery, PE components) through different coolant lines. This universal cooling system reduces device complexity compared to having separate cooling systems for each component, while still meeting the specific cooling needs of each through controlled fluid distribution.
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 system improves interior cooling performance, manages temperatures of batteries and PE components, and implements a heat pump, ensuring energy efficiency while maintaining a compact design.
Implementation Method 1
a first heat exchanger configured to exchange heat with the evaporator of the refrigerant circuit
Implementation Method 2
an internal heat exchanger configured to adjust a temperature of air-conditioning air through heat exchange with a coolant
Implementation Method 3
a second heat exchanger configured to exchange heat with the condenser of the refrigerant circuit
Data Source
AI summary
An embodiment integrated thermal management system includes a refrigerant circuit including a compressor, a condenser, an expander, and an evaporator, a first coolant line including a first heat exchanger configured to exchange heat with the evaporator of the refrigerant circuit and an internal heat exchanger configured to adjust a temperature of air-conditioning air through heat exchange with a coolant, first and second switching valves respectively disposed at front and rear ends of the internal heat exchanger in the first coolant line, a second coolant line connected to the first and second switching valves and including a second heat exchanger configured to exchange heat with the condenser of the refrigerant circuit, a third coolant line branching off from the first coolant line and including a battery, and a fourth coolant line branching off from the first coolant line and including a PE component.