Reversible Accumulator Filter for EV Heat Pump Systems
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Solution Overview
Problem
Current air conditioning systems in electric vehicles face challenges with energy consumption, battery overheating, and filter inefficiency, particularly in heat pump systems where filters struggle to retain impurities and particles smaller than 40 microns, leading to blockages and pressure drops.
Innovation Solution
A modular multistage filter with series-connected filtering units of varying capacities, a molecular sieve for water absorption, and a check valve to prevent dirt circulation, designed for integration into electric or hybrid vehicle air conditioning systems, capable of filtering particles down to a few tens of microns and operating within specific temperature and pressure ranges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If heat pump systems use higher fluid flow rates to maximize heat utilization, then heat extraction efficiency is improved, but system control complexity increases
Solution Approach 1:
The system dynamically adjusts refrigerant flow distribution between the evaporator and battery cooling circuit based on real-time thermal demands. The reversible four-way valve and expansion valves enable dynamic control of flow rates to optimize heat extraction while managing system complexity through adaptive rather than static configuration
Solution Approach 2:
The heat pump system serves multiple functions simultaneously: cabin heating/cooling and battery thermal management. By integrating both functions into a single refrigerant circuit with strategic component placement, the system maximizes heat utilization across different operating modes without proportionally increasing control complexity
2Power
If heat pump systems double the number of components and refrigerant flow to maximize heat utilization, then heat extraction efficiency is improved, but filter obstruction risk increases
Solution Approach 1:
The filtering function is segmented into multiple stages with different mesh sizes (40 microns and 10 microns) arranged in series. This segmentation allows each filter stage to handle different particle sizes, preventing single-point clogging and extending overall filter life while maintaining the high refrigerant flow rates needed for efficient heat extraction
Solution Approach 2:
The filter assembly is pre-configured with multiple filtering stages and strategic positioning before system operation begins. The first filter with larger mesh (40 microns) captures coarse particles first, protecting downstream components and the second finer filter (10 microns), thereby preventing premature obstruction of critical pathways in the doubled-component heat pump system
3Productivity
If quick recharge current is increased to reduce recharge time, then recharge speed is improved, but battery overheating increases
Solution Approach 1:
The system converts the harmful effect of battery overheating during quick charging into a beneficial resource by capturing the waste heat through the refrigerant circuit. The evaporator is positioned to absorb heat from the battery cooling plates, and this thermal energy is then utilized for cabin heating, allowing high-current fast charging without excessive temperature rise while eliminating the need for separate waste heat recovery components
4Reliability
If thermal management system is expanded to cool batteries in addition to cabin conditioning, then battery safety is improved, but system complexity increases
Solution Approach 1:
The existing heat pump components (compressor, evaporator, expansion valves, four-way valve) are made multi-functional to serve both cabin thermal management and battery cooling. The evaporator acts as both a cabin heat exchanger and a battery cooling device depending on refrigerant flow direction and valve configuration, eliminating the need for separate battery cooling components and reducing overall system complexity while ensuring battery safety
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 filter effectively retains impurities, prevents system blockages, and maintains low pressure drops, enhancing the thermal management and efficiency of electric vehicle air conditioning systems while ensuring safety by preventing overheating of lithium-ion batteries.
Implementation Method 1
a molecular sieve (4) configured to absorb water
Implementation Method 2
at least two filtering units (3) arranged in series, each filtering unit (3) having a predetermined filtering capacity
Data Source
Figure 1
Figure 1a
Figure 1b
AI summary
A filter (1) integrable into an automobile air conditioning system is described, comprising a container (2) having an inlet port (21) for the entry of a contaminated fluid and an outlet port (22) for the outlet of a filtered fluid, wherein the ports (21, 22) are configured to be connected to respective ducts; at least two filtering units (3) located in the container (2) and in fluid communication with each other and with the inlet port (21) and with the outlet port (22); each filtering unit (3) is configured to filter a fluid entering the inlet port (21); each filtering unit (3) has a predetermined filtering capacity at a first use greater than that of the upstream filtering unit (3).