Vehicle Heating System Using PTC and Heat Pump Segmentation

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Solution Overview

Problem

Hybrid and electric vehicles face challenges in heating their passenger cabins efficiently without activating the engine, especially at low ambient temperatures, as traditional heat pumps degrade in efficiency at lower temperatures.

Innovation Solution

A method involving a coolant loop heated by a positive temperature coefficient (PTC) heater and a heat pump, where the PTC heater is activated at low ambient temperatures and the heat pump takes over at higher temperatures, allowing for efficient cabin heating across a wide range of temperatures, and also enables engine heating to reduce fuel consumption and emissions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If a heat pump is used to heat the passenger cabin, then energy efficiency is improved, but heating performance deteriorates at low ambient temperatures

Engineering Contradiction:

Improveenergy efficiencyVSAvoidheating performance at low temperature

Core Design Contradiction:

Use of energy by moving objectVSTemperature

Solution Approach 1:

The heating system is segmented into two distinct components: a heat pump for efficient heating at moderate temperatures and a PTC heater for reliable heating at low temperatures. The controller segments the operating conditions and activates the appropriate heating component based on ambient temperature, ensuring both energy efficiency and adequate heating performance across all temperature ranges.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system changes the operating parameters by switching between two different heating mechanisms based on temperature. The heat pump operates efficiently when ambient temperature is above a threshold, while the PTC heater takes over when temperature drops below the threshold. This parameter-based switching resolves the contradiction by adapting the heating method to the ambient temperature condition.

Inventive Principle:

Principle #35Parameter changes

2Temperature

If the engine is activated to heat the passenger cabin, then heating capability is improved, but fuel consumption increases

Engineering Contradiction:

Improvecabin heating capabilityVSAvoidfuel consumption

Core Design Contradiction:

TemperatureVSUse of energy by moving object

Solution Approach 1:

The mechanical engine-driven heating system is replaced with an electrically-powered heating system consisting of a heat pump and PTC heater. This substitution eliminates the need to run the engine solely for cabin heating, thereby reducing fuel consumption while maintaining effective heating capability through electrically-powered thermal management components.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The heating system serves itself by using the vehicle's existing electrical infrastructure to power the heat pump and PTC heater, eliminating the need for external fuel-based heating. The system leverages the vehicle's electrical energy storage and powertrain to provide heating without requiring engine operation,实现ing self-sufficient electric heating.

Inventive Principle:

Principle #25Self-service

3Use of energy by moving object

If the engine is stopped to conserve fuel, then fuel economy is improved, but cabin heating capability deteriorates

Engineering Contradiction:

Improvefuel economyVSAvoidcabin heating capability

Core Design Contradiction:

Use of energy by moving objectVSTemperature

Solution Approach 1:

The heating system is designed with multi-functionality to operate effectively whether the engine is running or stopped. The heat pump and PTC heater can provide cabin heating independently of engine operation, making the heating capability universal across different engine states. This allows the vehicle to maintain fuel economy by keeping the engine stopped while still providing adequate cabin heating through electrically-powered components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 approach improves cabin heating in electric and hybrid vehicles, reduces fuel consumption and emissions, and extends the electric propulsion range by minimizing battery charge usage for heating.

Implementation Method 1

increasing temperature of a coolant in a coolant loop that includes a heater core via supplying electrical current to a positive temperature coefficient (PTC) heater

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

increasing temperature of the coolant via heat transferred from a heat pump

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS10336158B2Method and system for heating a vehicle

Publication Date: 2019.07.02 FORD GLOBAL TECH LLC

AI summary

Methods and system for providing heat to a vehicle are presented. In one example, a positive temperature coefficient (PTC) heater provides heat to a passenger cabin and an engine via heating engine coolant. Additionally, a heat pump may supply heat to the passenger cabin via heating the engine coolant.