Vehicle Heat Pump Layout for Shared Battery and Motor Cooling
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Solution Overview
Problem
Current vehicle heat pump systems for electric and hybrid vehicles are complex, leading to increased size, weight, and noise due to separate cooling circuits for batteries and electric modules, which complicates the layout and reduces ride comfort.
Innovation Solution
A simplified heat pump system using a single chiller for battery cooling and another chiller to recover waste heat from both the electric and battery modules, with a shared refrigerant and coolant heat exchange mechanism, reducing the number of valves and pipes, and optimizing temperature control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate cooling circuits are used for battery and electric module, then cooling performance is ensured, but system complexity and weight increase
Solution Approach 1:
The patent merges the battery cooling circuit and electric module cooling circuit into a single integrated cooling system. The coolant flows through both the battery module and electric module sequentially in one circuit, eliminating the need for separate cooling loops while maintaining adequate cooling performance for both components.
Solution Approach 2:
The cooling system is designed with multi-functionality to serve multiple purposes: it cools both the battery module and electric module using the same coolant circuit, and can also function as a heat pump system for interior heating. This universal design reduces overall system complexity while maintaining reliable cooling for all thermal management needs.
2Reliability
If separate cooling circuits are used for battery and electric module, then cooling performance is ensured, but weight increases
Solution Approach 1:
By combining the battery cooling and electric module cooling into one integrated circuit, the patent eliminates redundant pipes, valves, and pumps that would be required for separate systems. This merging directly reduces the overall weight of the thermal management system while maintaining effective cooling for both components.
3Ease of operation
If multiple valves are used for connecting cooling pipes, then cooling control is improved, but noise and vibrations increase
Solution Approach 1:
The patent reduces the number of valves by merging the cooling circuits, thereby minimizing the sources of noise and vibration. The simplified single-circuit design requires fewer switching operations and fewer valve components, directly reducing the harmful noise and vibrations that would otherwise be transmitted to the vehicle interior.
4Reliability
If separate cooling circuits are used, then battery temperature control is improved, but manufacturing cost increases
Solution Approach 1:
By integrating the battery cooling and electric module cooling into a single circuit, the patent reduces the total quantity of pipes, connectors, valves, and other components required. This consolidation directly lowers manufacturing costs through reduced material usage and simpler assembly processes, while still maintaining effective temperature control for the battery through the shared coolant flow.
5Reliability
If complex pipe layout is used for separate cooling systems, then cooling coverage is improved, but space utilization decreases
Solution Approach 1:
The patent merges the battery cooling and electric module cooling into one compact circuit arrangement, eliminating the need for extensive separate pipe networks. This integrated design reduces the overall space required for pipe routing in the engine compartment, improving space utilization while still providing adequate cooling coverage for both the battery module and electric module through the shared coolant path.
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 configuration simplifies the system, reduces weight and manufacturing costs, improves heating efficiency, and enhances ride comfort by efficiently managing battery temperatures, thereby increasing vehicle range and space utilization.
Implementation Method 1
the first chiller exchanges heat between a second coolant selectively introduced thereinto and a refrigerant to control a temperature of the coolant
Implementation Method 2
the second chiller recovers waste heat from a third coolant selectively introduced thereinto to raise a temperature of the refrigerant by exchanging heat between the coolant and the refrigerant
Data Source
AI summary
Disclosed herein is a heat pump system for a vehicle having a battery module and an electric module. The heat pump system includes: a first cooling line connected to the battery module and having a coolant flowing therein; a chiller disposed on the first cooling line and connected to a refrigerant line of an air conditioning system through a connection line, and exchanging heat between a coolant selectively introduced therein and a refrigerant to control a temperature of the coolant; a cooling system including a radiator connected to a cooling line and a first pump circulating the coolant along the second cooling line so as to cool an electric module, and connected to the first cooling line through a first valve; and a bypass line selectively connecting the connection line and the refrigerant line to each other through a second valve provided on the refrigerant line.