Outside Heat Exchanger De-Icing Using EV Waste Heat
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Solution Overview
Problem
Icing of outside heat exchangers in electric vehicles can disrupt heat pump operation and reduce heating efficiency, as existing methods either delay de-icing or use less efficient electrical heaters, and there is a need to prevent excessive thermocycling and maintain heating demand while minimizing component degradation.
Innovation Solution
A method involving multiple de-icing modes based on ambient temperature and high voltage battery conditions, utilizing the high voltage coolant heater, battery heat, and power electronics waste heat to efficiently thaw the outside heat exchanger, while controlling air flow and coolant circulation to prevent ice buildup and maintain system performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing methods delay de-icing or use electrical heaters, then heating efficiency is reduced, but component degradation is minimized
Solution Approach 1:
The patent converts the waste heat generated by power electronics (which would otherwise be discarded) into a useful resource for de-icing the outside heat exchanger. This transforms a harmful effect (heat waste causing ice formation) into a beneficial effect (using that heat to melt ice), thereby improving heating efficiency without requiring additional energy input or causing component degradation.
Solution Approach 2:
The system uses its own internally generated waste heat from power electronics to service the de-icing requirement of the outside heat exchanger. This self-service approach eliminates the need for external heating sources, maintains heating efficiency, and avoids the component degradation associated with electrical heaters by utilizing the existing thermal resources within the system.
2Object-affected harmful factors
If de-icing is performed frequently, then ice buildup is prevented, but excessive thermocycling occurs
Solution Approach 1:
The patent implements preliminary action by proactively using waste heat to prevent ice buildup on the outside heat exchanger before it significantly impedes system performance. The controller monitors conditions and initiates de-icing operations using available waste heat from power electronics, addressing the ice prevention need before it becomes a critical issue, thereby reducing the frequency of aggressive de-icing cycles.
Solution Approach 2:
The system changes the thermal parameters of the outside heat exchanger by introducing waste heat from power electronics, altering the temperature conditions to prevent ice formation. This parameter change approach allows for gentle, continuous thermal management rather than aggressive on/off cycling, reducing thermocycling frequency while effectively preventing ice buildup.
3Temperature
If heat pump is turned off for de-icing, then outside heat exchanger is heated, but heating demand is not met
Solution Approach 1:
The patent merges the de-icing function with the power electronics cooling function by combining their thermal management needs. The waste heat from power electronics that would otherwise be discarded is redirected to heat the outside heat exchanger, simultaneously achieving de-icing and maintaining cabin heating without requiring the heat pump to shut down.
Solution Approach 2:
The patent introduces an intermediary thermal management system that captures waste heat from power electronics and transfers it to the outside heat exchanger. This intermediary approach allows the heat pump to remain operational for cabin heating while the intermediary system handles the de-icing function using available waste heat, eliminating the need to shut down the heat pump.
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 method effectively prevents ice buildup on the outside heat exchanger, maintains heating efficiency, and reduces component stress by using optimal heat sources and controlling air flow, ensuring efficient de-icing and prolonged system performance.
Implementation Method 1
using coolant from a high voltage heater to heat the cabin and/or to heat the high voltage battery
Implementation Method 2
circulating coolant through the high voltage battery and the outside heat exchanger in a combined fluid circuit to heat the outside heat exchanger
Implementation Method 3
utilizing heat from the high voltage battery to heat the outside heat exchanger by causing the coolant that has been heated by the high voltage battery to flow through the outside heat exchanger
Implementation Method 4
opening the grill shutters and actuating the electric fan to increase flow of ambient air over the outside heat exchanger
Implementation Method 5
VAPOR INJECTION HEAT PUMP
Data Source
AI summary
A method of detecting and mitigating icing of an outside heat exchanger in an electric vehicle including a heat pump. Various sources of heat may be utilized to de-ice an outside heat exchanger of the heat pump. The sources of heat may include one or more of vehicle electronics, a high voltage (“HV”) battery, and an HV coolant heater. Pre-defined criteria may be utilized to determine the actions to be taken to de-ice the outside heat exchanger and/or to prevent icing of the outside heat exchanger.