Water-Heating PTC Heater for Fuel Cell Thermal Management
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Solution Overview
Problem
Fuel cell vehicles lack a sufficient heat source for their heating systems, limiting the efficiency of heat pumps and requiring additional heat sources like electric heaters, as they do not generate enough heat like conventional engine-powered vehicles.
Innovation Solution
A thermal management system for vehicles that includes a water-heating type PTC heater, which is controlled to maintain coolant temperature above ambient during battery charging, using a controller to turn on the PTC heater when necessary, and utilizing waste heat recovery to supply heat to the refrigerant line, ensuring a consistent heat source during heating modes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a heat pump system is used in fuel cell vehicles, then heating function is provided, but insufficient heat source causes deterioration of heat pump efficiency
Solution Approach 1:
The PTC heater is operated during battery charging to preheat the coolant before the heat pump operates. This preliminary heating action ensures that the coolant reaches a temperature sufficient for the heat pump to operate efficiently, thereby resolving the contradiction between providing heating function and maintaining heat pump efficiency.
Solution Approach 2:
The PTC heater acts as an intermediary device that bridges the heat gap between the battery charging process and the heat pump operation. By introducing this intermediate heating source, the system ensures continuous and efficient heating performance, addressing the insufficient heat source problem.
2Temperature
If a separate heat source such as an electric heater is provided, then heating function is secured, but device complexity increases
Solution Approach 1:
The PTC heater is integrated into the existing battery cooling system, allowing it to serve dual functions: cooling the battery during high-load operation and heating the coolant during charging. This multi-functionality approach secures the heating function without significantly increasing system complexity.
Solution Approach 2:
The battery cooling system is designed to serve itself by utilizing the PTC heater that is already part of the system architecture. The same system that cools the battery during operation can also heat the coolant during charging, eliminating the need for completely separate heating infrastructure.
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 secures a heat source for heating in fuel cell vehicles, improving battery efficiency and heat pump performance by maintaining coolant temperature above required levels, reducing energy consumption for heating, and enhancing overall fuel efficiency.
Implementation Method 1
water-heating type PTC heater
Implementation Method 2
waste heat recovery chiller supplying heat to the refrigerant line
Implementation Method 3
battery chiller
Data Source
AI summary
A thermal management system for a vehicle and method for controlling a water-heating type PTC heater thereof by controlling a PTC heater that uses water for heating, in which a heat source for heating is secured by operating the water-heating type PTC heater and thereby additionally heating a coolant, while charging a battery, in a thermal management system for a vehicle, during a heating mode, in which: refrigerant circulates through a second heat exchanger, a waste heat recovery chiller, a compressor and an indoor heat exchanger; and the coolant passes through a water-cooling type battery module, the water-heating type PTC heater, a battery chiller, electric parts and the waste heat recovery chiller.