Underbody Thermal Module Layout for EV Heating and Battery Temperature
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Solution Overview
Problem
Electric vehicles face challenges in maintaining optimal battery performance and lifespan due to temperature fluctuations, as they lack an engine-based heating system, leading to reduced travel distance and inefficient energy use.
Innovation Solution
An integrated thermal management module is provided on the underbody of the vehicle, comprising a housing with cooling/heating and heat exchanging ducts, refrigerant storage, and circulation components, including a vaporization core, condensing core, radiator, and outdoor condenser, to manage thermal conditions efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If an electric vehicle uses electricity from the battery to operate a heater for indoor heating, then heating function is achieved, but the travel distance of the electric vehicle is significantly reduced
Solution Approach 1:
The patent combines the air conditioning system and thermal management system into a single integrated module, sharing common components such as the housing, refrigerant circulation path, and heat exchangers. This integration allows the system to efficiently manage both cooling and heating functions while reducing overall energy consumption by optimizing thermal transfer pathways and eliminating redundant components.
2Device complexity
If an electric vehicle lacks an engine-based heating system, then the vehicle structure is simplified, but it becomes difficult to maintain optimal temperature environment for the battery
Solution Approach 1:
The integrated thermal management module serves multiple functions: it provides indoor air conditioning, cools the battery pack, and manages thermal conditions for other vehicle components. By using a single multi-functional system instead of separate engine-based heating and dedicated battery cooling systems, the patent simplifies the overall vehicle structure while ensuring optimal temperature control for the battery.
3Volume of moving object
If thermal management components are integrated into a module on the underbody, then space utilization is enhanced and fabrication costs are reduced, but the device complexity increases
Solution Approach 1:
The patent integrates multiple thermal management components including the housing, cooling/heating duct, heat exchanging duct, vaporization core, condensing core, refrigerant storage, and circulation parts into a single modular assembly mounted on the vehicle underbody. This consolidation reduces the total volume occupied by separate systems, improves space utilization, and simplifies installation while the modular design manages the inherent complexity through standardized interfaces and compact arrangement.
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 space utilization, reduces fabrication costs, and improves vehicle body strength while effectively managing indoor air conditioning and heat for electric vehicles, maximizing cabin space and improving battery performance.
Implementation Method 1
The vaporization core and the condensing core may be connected to a refrigerant line on which a compressor and an expansion valve are provided, such that refrigerant circulates
Implementation Method 2
a vaporization core for indoor cooling and a condensing core for indoor heating
Implementation Method 3
The radiator and the outdoor condenser may be positioned in a flow path provided in an inside space of the heat exchanging duct
Data Source
AI summary
A thermal management module for a vehicle includes: a housing disposed on a cross member between side frames arranged on both sides of an underbody of the vehicle on which wheels and a drive unit are positioned; a cooling/heating heat exchanger; an outdoor heat exchanger; a refrigerant storage; and a refrigerant circulation part. The housing includes a cooling/heating duct connected to an upper body of the vehicle, and a heat exchanging duct connected to the outside of the vehicle. The cooling/heating heat exchanger and the outdoor heat exchanger are disposed on the cooling/heating duct and the heat exchanging duct of the housing. The refrigerant storage and the refrigerant circulation part are provided on sides of the cooling/heating duct and the heat exchanging duct of the housing.