HVAC system for electric vehicle with driving range extension

Patent metadata

Field	Value
Publication number	US-9809083-B2
Application number	US-201615052945-A
Country	US
Kind code	B2
Filing date	Feb 25, 2016
Priority date	Feb 27, 2015
Publication date	Nov 7, 2017
Grant date	Nov 7, 2017

Abstract

A heat pump cooling and heating system for an electric vehicle includes a range extending PCM heat exchanger ( 24 ), with a single acting phase change material with a melt temperature between the two comfort temperatures associated with cooling and heating, respectively. In a charging mode, as the vehicle batteries are charged, the same exterior current source runs the compressor ( 10 ), charging the PCM exchanger ( 24 ) with heat or “cold.” During an initial range extending mode, the PCM exchanger/reservoir ( 24 ) serves as the heat source or heat sink. The PCM material does not directly heat or cool the air, as is conventional, allowing a single reservoir material to be used in both heating and cooling modes.

First claim

The invention claimed is:

1. A heating and cooling system for an electric vehicle having batteries chargeable during a stationary charging period, the system comprising:
an exterior heat exchanger capable of acting as an evaporator to draw heat from ambient air in a standard heating mode and as a condenser to dump heat to the ambient air in a standard cooling mode, and
a cabin heat exchanger capable of acting as a condenser to dump heat to cabin air in the standard heating mode and as an evaporator to draw heat from the cabin air in the standard cooling mode,
a duct arrangement adapted to selectively establish or shut off a temporary thermal exchange between the cabin heat exchanger and the ambient air during the stationary charging period,
a single energy storage heat exchanger assembly surrounded by phase change material, the single energy storage heat exchanger assembly being operatively arranged in parallel to the exterior heat exchanger, and
a switching valve having a first switching position and a second switching position, wherein in the first switching position, the switching valve connects the single energy storage heat exchanger assembly in series with the cabin heat exchanger and wherein in the second switching position, the switching valve connects the exterior heat exchanger in series with the cabin heat exchanger.

2. The system according to claim 1 , wherein the phase change material has a phase change temperature between a lower comfort mode temperature associated with a heating mode and a higher comfort mode temperature associated with a cooling mode.

3. The system according to claim 1 , wherein the duct arrangement is configured to establish the thermal exchange between the cabin heat exchanger and the ambient air only during the stationary charging period.

4. The system according to claim 1 , further comprising an expansion valve operatively arranged between the switching valve and the cabin heat exchanger, wherein the single energy storage heat exchanger and the exterior heat exchanger are operatively arranged relative to the switching valve on a side opposite the expansion valve.

5. The system according to claim 1 , further comprising a reversing valve and a compressor outputting compressed refrigerant, wherein the reversing valve has a first directional position, in which the reversing valve directs the compressed refrigerant to the cabin heat exchanger in a heating mode, and a second directional position, in which the reversing valve directs the compressed refrigerant to the single energy storage heat exchanger assembly in a cooling mode when the switching valve is in the first switching position.

6. The system according to claim 5 , wherein the reversing valve in the second directional position directs the compressed refrigerant to the exterior heat exchanger in a cooling mode when the switching valve is in the second switching position.

7. The system according to claim 5 , wherein the compressor is configured to be powered by an external power source during the stationary charging period.

8. The system according to claim 5 , wherein the system has six modes of operation, which include a cooling charging mode, range extending cooling operation, a standard cooling operation, a heating charging mode, a range extending heating operation, and a standard heating operation,
wherein both the cooling charging mode and the hearing charging mode are limited to times during the stationary charging period,
wherein during the cooling charging mode and during the range extending heating operation, the switching valve is in the first switching position and the reversing valve is in the first directional position;
wherein during the heating charging mode and during the range extending cooling operation, the switching valve is in the first switching position and the reversing valve is in the second directional position;
wherein during the standard cooling operation, the switching valve is in the second switching position and the reversing valve is in the second directional position; and
wherein during the standard heating operation, the switching valve is in the second switching position and the reversing valve is in the first directional position.

9. The system according to claim 8 , wherein upon detecting a need for a cooling operation, the system is configured to perform the range extending cooling operation until the single energy storage heat exchanger assembly has absorbed enough heat that the range extending cooling operation is no longer more efficient than the standard cooling operation.

10. The system according to claim 8 , wherein the system is configured to switch the switching valve from the first switching position to the second switching position to change the mode of operation from the range extending cooling operation to the standard cooling operation when the range extending cooling operation is no longer more efficient than the standard cooling operation.

11. The system according to claim 8 , wherein upon detecting a need for a heating operation, the system is configured to perform the range extending heating operation until the single energy storage heat exchanger assembly has cooled down sufficiently that the range extending heating operation is no longer more efficient than the standard heating operation.

12. The system according to claim 8 , wherein the system is configured to switch the switching valve from the first switching position to the second switching position to change the mode of operation from the range extending heating operation to the standard heating operation when the range extending heating operation is no longer more efficient than the standard heating operation.

Assignees

• Mahle Int Gmbh

Inventors

• Xia Yanping
• Kadle Prasad S
• Leitzel Lindsey L
• Wang Mingyu
• Craig Timothy D

Classifications

• B60H1/143

  the heat being derived from cooling an electric component, e.g. electric motors, electric circuits, fuel cells or batteries · CPC title

• B60H2001/00178

  comprising an air passage from the HVAC box to the exterior of the cabin · CPC title

• B60H1/00907

  where the flow direction of the refrigerant changes and an evaporator becomes condenser · CPC title

• B60H2001/00949

  comprising additional heating/cooling sources, e.g. second evaporator · CPC title

• B60H1/00492 Primary

  comprising regenerative heating or cooling means, e.g. heat accumulators · CPC title