Integrated Vehicle Heat Pump Using One Chiller and Waste Heat
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Solution Overview
Problem
Existing vehicle heat pump systems for electric and hybrid vehicles are inefficient, leading to decreased heating performance, increased electricity consumption, and poor ride comfort due to separate battery cooling systems and complex pipe layouts, which also result in noise and vibration.
Innovation Solution
A heat pump system that uses a single chiller for a vehicle, where a coolant and refrigerant exchange heat to adjust the battery module temperature, incorporating a sub-centralized energy module and gas injection unit to enhance heating performance and efficiency, while minimizing the use of electric heaters and simplifying the system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate battery cooling system and heat pump system are provided, then battery temperature control is achieved, but system complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the battery cooling system and heat pump system into a single integrated system. The heat pump system's refrigerant cycle is used to provide both heating for the vehicle interior and cooling for the battery module, eliminating the need for a separate battery cooling system. This merging reduces system complexity and manufacturing cost while maintaining reliable battery temperature control.
Solution Approach 2:
The heat pump system is designed to perform multiple functions: heating the vehicle interior, cooling the battery module, and providing climate control. By making the heat pump system universal, it replaces both the traditional air conditioner and the separate battery cooling system, thereby reducing overall system complexity while achieving reliable battery temperature control.
2Reliability
If multiple valves are used for connecting separate systems, then battery cooling is achieved, but noise and vibration increase
Solution Approach 1:
By merging the battery cooling function into the heat pump system, the patent eliminates the need for multiple separate valves that would connect independent systems. The integrated design reduces the number of valve operations, thereby minimizing noise and vibration transmission to the vehicle interior while maintaining effective battery cooling.
3Temperature
If electric heater is used for heating, then heating is achieved, but electricity consumption increases
Solution Approach 1:
The patent utilizes waste heat from the battery module and electrical components as a heat source for heating the vehicle interior. By converting the harmful waste heat into a useful resource, the system provides heating functionality while minimizing electricity consumption, as the heat pump requires significantly less energy compared to electric heaters.
Solution Approach 2:
The system changes the operating parameters by using the heat pump's refrigerant cycle to transfer heat from the battery module and electrical components to the vehicle interior. This parameter change from direct electric heating to heat transfer enables efficient heating with reduced electricity consumption.
4Reliability
If complex pipe layout is used for separate systems, then battery cooling and heating are achieved, but manufacturing cost and weight increase
Solution Approach 1:
The patent merges the battery cooling system and heat pump system into a single integrated system, which significantly simplifies the pipe layout. By combining the refrigerant circuits and heat exchange components, the system reduces the total amount of piping required, thereby decreasing both manufacturing cost and system weight while maintaining effective battery temperature control.
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 improves heating performance, reduces electricity consumption, optimizes battery module temperature control, and simplifies the system, thereby enhancing ride comfort and reducing manufacturing costs and weight.
Implementation Method 1
a chiller provided on the refrigerant connection line, connected to an electrical component and a battery module through a coolant line, respectively, and heat-exchanging a coolant introduced in the chiller with the first refrigerant
Implementation Method 2
a sub-centralized energy (CE) module including a second evaporator provided in the refrigerant connection line, fluidically connected to the air conditioner through the refrigerant connection line or the first refrigerant line, to adjust a temperature of the first refrigerant by selectively heat-exchanging thermal energy which is generated when condensing and evaporating of a second refrigerant circulating along a second refrigerant line with the first refrigerant
Implementation Method 3
a high-temperature and high-pressure gaseous refrigerant which is compressed by the compressor
Implementation Method 4
a high-temperature and high-pressure gaseous refrigerant which is compressed by the compressor is condensed through the condenser
Implementation Method 5
then is evaporated by the evaporator through the receiver drier and the expansion valve to lower the indoor temperature and humidity in cooling mode
Implementation Method 6
a gas injection unit is provided in the air conditioner to increases a flow rate of the first refrigerant circulating in the first refrigerant line by bypassing a part of the first refrigerant to the first compressor
Data Source
AI summary
A heat pump system for a vehicle utilizes one chiller in which a coolant and a refrigerant are heat-exchanged to adjust a temperature of a battery module, and utilizes a sub-CE module (sub-centralized energy module) with waste heat of an electrical component in a heating mode of the vehicle to improve heating efficiency.