Vehicle Thermal Loop Integration for Waste-Heat Cabin Heating
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Solution Overview
Problem
Electric vehicles face challenges in efficient thermal management due to the large amount of heat produced by battery modules and electrical components, leading to space and energy efficiency issues with conventional cooling systems.
Innovation Solution
A thermal management system that recirculates coolant to cool electrical components and uses waste heat for interior heating, integrating a radiator, water pumps, and valves with an air conditioner device to simplify the system and reduce HVAC module components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate cooling system is applied to control the temperature of electrical components and battery module, then temperature control reliability is improved, but device complexity increases and space consumption increases
Solution Approach 1:
The patent combines the cooling system for electrical components and the HVAC system into a single integrated thermal management system. The coolant circulation system serves dual purposes: cooling electrical components through dedicated cooling plates and providing climate control through the HVAC module, thereby reducing system complexity while maintaining temperature control reliability
Solution Approach 2:
The coolant circulation system is designed to perform multiple functions simultaneously. The same coolant loop that cools electrical components also provides heating and cooling functions for the HVAC system, making the system universal and multi-functional rather than requiring separate dedicated systems
2Reliability
If the capacity of cooling system is increased to cool larger electrical components, then temperature control effectiveness is improved, but power consumption increases
Solution Approach 1:
The patent converts the waste heat generated by electrical components into a useful resource for HVAC heating operations. During heating mode, the coolant that absorbs heat from electrical components is directed to the HVAC heating system, transforming what would be wasted energy into a beneficial heating source, thereby improving temperature control effectiveness without increasing power consumption
Solution Approach 2:
The electrical components themselves serve as heat sources for the HVAC heating system. The waste heat generated during their operation is recovered and utilized for interior heating, allowing the system to self-service its heating needs without requiring additional external energy input
3Loss of energy
If waste heat from electrical components is used for interior heating, then heating efficiency is improved and energy loss is reduced, but system control complexity increases
Solution Approach 1:
The patent implements dynamic control of coolant flow distribution based on real-time thermal demands. The system can dynamically switch between different operating modes (electrical component cooling only, HVAC cooling, HVAC heating with waste heat recovery) and adjust coolant flow paths using control valves, allowing flexible adaptation to varying conditions while managing control complexity through standardized control mechanisms
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 enhances heating efficiency, reduces system complexity and weight, and optimizes space by utilizing waste heat for interior heating and cooling, while minimizing manufacturing costs and labor.
Implementation Method 1
the condenser connected to the first connection line to recirculate the coolant inside and heat-exchanging the refrigerant supplied through the refrigerant line with the coolant
Implementation Method 2
an evaporator connected to the condenser through the refrigerant line and evaporating the refrigerant
Implementation Method 3
heating the interior of the vehicle using waste heat generated from electrical components
Data Source
AI summary
A thermal management system for a vehicle includes: a cooling apparatus including a radiator, a first water pump, and a first valve that are connected by a coolant line and recirculating a coolant in the coolant line so as to cool at least one electrical component provided on the coolant line, a first connection line selectively connected to the coolant line through the first valve, a second connection line selectively connected to the first connection line through the second valve, and a heater provided on the second connection line, wherein the first connection line is provided with a condenser included in an air conditioner device, and the heater is provided inside an HVAC module included in the air conditioner device.