Vehicle Thermal Management Layout for Modular Heat Pump Heating

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Solution Overview

Problem

Conventional thermal management systems for electric vehicles are complex, heavy, costly, and difficult to modularize due to the increased number of components and refrigerant requirements, leading to inefficiencies in cooling and heating operations.

Innovation Solution

A vehicle thermal management system with integrated heating and cooling heat exchangers, a mixing tank, and multiple valves to control coolant flow, allowing for various air-conditioning modes and utilizing waste heat from electronic parts and batteries for heating, while reducing the number of heat exchangers and refrigerant valves.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a conventional direct heating type heat pump system is used, then heating function is achieved, but the system configuration becomes complicated and weight increases due to increased number of components

Engineering Contradiction:

Improveheating functionVSAvoidsystem configuration

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The patent combines the heating heat exchanger and cooling heat exchanger into a single integrated heat exchanger unit. This merging of functions reduces the number of separate components needed in the thermal management system, simplifying the overall system configuration while maintaining both heating and cooling capabilities through strategic placement of valves and flow control mechanisms.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated heat exchanger serves multiple functions: it acts as both a heating heat exchanger and a cooling heat exchanger depending on the flow direction and valve configuration. This multi-functionality eliminates the need for separate dedicated heating and cooling heat exchangers, reducing component count and system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Temperature

If a conventional thermal management system with multiple heat exchangers is used, then cooling and heating operations are achieved, but weight and manufacturing cost increase

Engineering Contradiction:

Improvecooling and heating operationsVSAvoidsystem weight

Core Design Contradiction:

TemperatureVSWeight of moving object

Solution Approach 1:

The patent merges multiple heat exchanger functions into a single integrated unit, directly reducing the total weight of the thermal management system. By eliminating redundant components and consolidating heat exchange functions, the system achieves both cooling and heating operations with reduced mass compared to conventional systems using separate heat exchangers.

Inventive Principle:

Principle #5Merging (Combining)

3Use of energy by moving object

If a conventional thermal management system with dispersed refrigerant components is used, then refrigerant circulation is achieved, but vehicle assemblability deteriorates due to difficulty in modularization

Engineering Contradiction:

Improverefrigerant circulationVSAvoidvehicle assemblability

Core Design Contradiction:

Use of energy by moving objectVSEase of manufacture

Solution Approach 1:

The patent integrates refrigerant circulation components and heat exchanger functions into modular assemblies that can be easily installed and configured in the vehicle. By consolidating dispersed refrigerant components into integrated units with standardized connections, the system improves vehicle assemblability while maintaining effective refrigerant circulation for both heating and cooling operations.

Inventive Principle:

Principle #5Merging (Combining)

4Loss of energy

If a heat pump system with chiller and multiple heat exchangers is used, then waste heat recovery is achieved, but the number of components and refrigerant charging amount increase

Engineering Contradiction:

Improvewaste heat recoveryVSAvoidrefrigerant charging amount

Core Design Contradiction:

Loss of energyVSQuantity of substance

Solution Approach 1:

The patent combines the chiller and heat exchanger functions into an integrated configuration that recovers waste heat from the battery and electronic parts more efficiently. By merging these functions and optimizing the refrigerant flow paths through strategic valve control, the system achieves effective waste heat recovery with reduced refrigerant charging requirements compared to conventional systems with separate components.

Inventive Principle:

Principle #5Merging (Combining)

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 simplifies refrigerant lines, reduces weight and cost, improves heat pump heating performance, and efficiently cools and heats the vehicle interior, while actively managing power consumption based on battery heat generation.

Implementation Method 1

a heating heat exchanger which exchanges heat with air within an air-conditioning case to heat the air

Methodology Applied