Slim-Type Heat Management System Using Two Three-Way Expansion Valves
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Solution Overview
Problem
Conventional heat management systems for electric vehicles require a large number of parts, leading to increased costs, complexity, and challenges in packaging, particularly for small electric vehicles prioritizing profitability over performance.
Innovation Solution
A slim-type heat management system for electric vehicles utilizing a minimum number of parts, including two three-way expansion valves, to implement various heat management modes such as heat pump dehumidification, dehumidification max, indoor cooling, battery cooling, and heat pump heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional heat management system is constructed as a heat pump system capable of implementing various heat management modes, then the system can provide comprehensive heating, cooling, and dehumidification functions, but the number of parts increases to four or more refrigerant valves, expansion valves, cooling water valves, waste heat recovery chillers, air conditioner pipes, and other components
Solution Approach 1:
The outdoor heat exchanger is designed to serve dual functions as both a condenser and an evaporator depending on the operating mode. By controlling the flow direction of the refrigerant through the three-way expansion valves, the same heat exchanger component can reject heat to the outdoor environment during cooling modes or absorb heat from the outdoor environment during heating modes, eliminating the need for separate condenser and evaporator components
Solution Approach 2:
Multiple refrigerant flow paths are merged into a single integrated circuit. The three-way expansion valves are configured to redirect refrigerant flow such that the indoor heat exchanger and outdoor heat exchanger can operate in series or parallel configurations depending on the mode, combining what would traditionally be separate cooling and heating circuits into one unified system
2Adaptability or versatility
If a conventional heat management system includes multiple valves and expansion devices, then various operating modes can be implemented, but the cost increases
Solution Approach 1:
The three-way expansion valves are designed to perform multiple functions: they control refrigerant flow distribution to different heat exchangers, regulate expansion into different circuits, and enable mode switching between heating and cooling operations. This multi-functionality reduces the total valve count compared to conventional systems that would require separate valves for each function
Solution Approach 2:
The system uses a simplified valve configuration that replicates the essential flow control functions of more complex conventional systems. By strategically positioning just two three-way expansion valves at key junctions in the refrigerant circuit, the system achieves the same operational flexibility as systems with multiple specialized valves, thereby reducing component costs
3Adaptability or versatility
If a conventional heat management system includes multiple cooling circuits and components, then various operating modes can be implemented, but the complexity and disadvantages of package layout for a room in which the PE parts are mounted increased
Solution Approach 1:
The refrigerant circuits for different heat management modes are merged into a single integrated loop. The three-way expansion valves are positioned to enable the refrigerant to flow through shared piping to reach both the indoor heat exchanger and outdoor heat exchanger, eliminating the need for separate parallel cooling circuits and reducing the overall volume required for component packaging
Solution Approach 2:
The outdoor heat exchanger serves as both condenser and evaporator, and the three-way expansion valves control flow to enable the same physical components to fulfill multiple operational roles. This multi-functionality reduces the number of discrete components that would otherwise require separate mounting spaces, thereby reducing the total package volume for the PE parts room
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 system enables efficient implementation of multiple heat management modes with a reduced number of parts, making it suitable for small electric vehicles and those prioritizing profitability over performance, while maintaining effective temperature control and defogging capabilities.
Implementation Method 1
a battery chiller connected to a 2-2 outlet of the second three-way expansion valve by a ninth refrigerant flow path
Implementation Method 2
an evaporator mounted inside the air conditioner casing and connected to the expansion valve by a sixth refrigerant flow path
Implementation Method 3
an inner condenser mounted inside an air conditioner casing and connected to a discharge portion of an electric compressor by a first refrigerant flow path
Data Source
AI summary
A slim-type heat management system for an electric vehicle is provided. The system includes various heat management modes using a number of parts including at least two three-way expansion valves. The various heat management modes include a heat pump dehumidification mode and a dehumidification max mode, which are for defogging, in addition to an indoor cooling mode, a battery cooling mode, and a heat pump mode for heating.