Vehicle Thermal Management With Antifreeze Bypass Frost Control

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Solution Overview

Problem

Existing thermal management systems for vehicles using highly flammable or toxic refrigerants face challenges in cooling both the battery and passenger compartment effectively while preventing frost formation and system complexity.

Innovation Solution

A thermal management system with a refrigerant circuit, antifreeze circuit, and chillers that control refrigerant and antifreeze flow rates to maintain temperatures above 0°C in the cooling core, preventing frost while efficiently cooling both the battery and passenger compartment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If the chiller cools the coolant to a temperature lower than 0°C to cool the high temperature battery, then the battery cooling performance is improved, but frost may form on the cooling core which decreases the passenger compartment cooling performance

Engineering Contradiction:

Improvecoolant temperatureVSAvoidcooling performance

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The patent applies dynamics by making the flow rate of coolant to the cooling core adjustable rather than fixed. The control unit dynamically changes the flow rate based on temperature conditions: when coolant temperature is below 0°C, the flow rate is reduced or stopped to prevent frost; when temperature is above 0°C, the flow rate is increased to improve cooling efficiency. This dynamic adjustment resolves the contradiction between achieving low temperatures for battery cooling and preventing frost formation.

Inventive Principle:

Principle #15Dynamics

2Object-affected harmful factors

If a highly flammable refrigerant or toxic refrigerant is used, then the global warming potential is reduced, but the evaporator cannot be placed in the passenger compartment from the viewpoint of protecting the passengers

Engineering Contradiction:

Improveglobal warming potentialVSAvoidsystem configuration

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The patent uses an intermediary substance (coolant) to transfer heat between the battery and the passenger compartment cooling system. Instead of placing the evaporator directly in the passenger compartment with flammable refrigerant, the system uses a coolant circuit that circulates between the battery cooling section and the cooling core in the passenger compartment. This intermediary approach allows the use of environmentally friendly refrigerants while maintaining safety by separating the refrigerant from the passenger space.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If the cooling core cools the air supplied to the passenger compartment with coolant at 0°C or lower, then the cooling efficiency is improved, but frost formation prevents satisfactory heat transfer

Engineering Contradiction:

Improvecooling efficiencyVSAvoidheat transfer performance

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent implements feedback control by using a temperature sensor to monitor coolant temperature and a control unit to adjust the flow rate accordingly. When the sensor detects coolant temperature at or below 0°C, the control unit automatically reduces or stops the flow to the cooling core to prevent frost formation. This feedback mechanism ensures that the system maintains optimal operating conditions, preventing frost while maximizing cooling efficiency when temperatures are appropriate.

Inventive Principle:

Principle #23Feedback

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 ensures effective cooling of both the battery and passenger compartment while using flammable refrigerants, preventing frost formation and simplifying installation by optimizing refrigerant and antifreeze flow control.

Implementation Method 1

The chiller is configured to transfer heat between the refrigerant and the antifreeze to cool the antifreeze

Methodology Applied