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DE-102025133665-A1 - Refrigeration system and heat pump arrangement for heating and cooling battery-powered vehicles and methods for their operation

DE102025133665A1DE 102025133665 A1DE102025133665 A1DE 102025133665A1DE-102025133665-A1

Abstract

The invention relates to a refrigeration system and heat pump arrangement for heating and cooling battery-powered vehicles, comprising a refrigerant circuit. - with a compressor (1), a heating condenser (2) or a water-cooled condenser (18), a second 3/2-way refrigerant valve with expansion function (3), an ambient heat exchanger (4), at least one evaporator (6) with associated refrigerant valve with expansion function (5) and a refrigerant path arranged parallel to the evaporator (6) via a chiller (9) with an upstream refrigerant valve with expansion function (10), wherein an internal heat exchanger (13), a refrigerant collector (11) and the evaporator (6) and the chiller (9) are connected to each other in various arrangements.

Inventors

  • Navid Durrani

Assignees

  • HANON SYSTEMS

Dates

Publication Date
20260513
Application Date
20250822
Priority Date
20241113

Claims (20)

  1. Refrigeration and heat pump arrangement for heating and cooling battery-powered vehicles, comprising a refrigerant circuit - with a compressor (1), a heating condenser (2) in the case of direct heat transfer or a water-cooled condenser (18) in the case of indirect heat transfer, a second 3/2-way refrigerant valve with expansion function (3), an ambient heat exchanger (4), at least one evaporator (6) with an associated refrigerant valve with expansion function (5), and a refrigerant path arranged parallel to the evaporator (6) via a chiller (9) with an upstream refrigerant valve with expansion function (10), wherein - the high-pressure side of the compressor (1) is connected to the heating condenser (2) or the water-cooled condenser (18) and to a valve inlet (23) of a first 3/2-way refrigerant valve with expansion function (8), and a second valve outlet (22) of the first 3/2-way refrigerant valve with Expansion function (8) is connected to a refrigerant receiver (11), and a first valve outlet (21) of the first 3/2-way refrigerant valve with expansion function (8) is connected to the ambient heat exchanger (4), and - a bypass line to the first 3/2-way refrigerant valve with expansion function (8) is provided, which can be shut off with a shut-off valve (17), and - a second valve outlet (22) of the second 3/2-way refrigerant valve with expansion function (3) is connected to the ambient heat exchanger (4), and a first valve outlet (21) of the second 3/2-way refrigerant valve with expansion function (3) is connected to a receiver (15) and a check valve (16), and - the ambient heat exchanger (4) is connected via the high-pressure side of an internal heat exchanger (12) to the check valve (16) and a refrigerant valve with expansion function (14). is connected, wherein - the receiver (15) and the refrigerant expansion valve (14) are connected to the refrigerant expansion valve (5) and the refrigerant expansion valve (10), wherein - the suction side of the compressor (1) is connected via the internal low-pressure side heat exchanger (13) to the evaporator (6) and via a refrigerant receiver (11) to the chiller (9), and the refrigerant receiver (11) and the chiller (9) are connected to the second valve outlet (22) of the first 3/2-way refrigerant expansion valve (8), or the suction side of the compressor (1) is connected via the internal low-pressure side heat exchanger (13) to the evaporator (6) and the chiller (9), and the second valve outlet (22) of the first 3/2-way refrigerant expansion valve (8) is connected to the refrigerant receiver (11). is or the suction side of the compressor (1) is connected via the refrigerant collector (11) and the internal heat exchanger low pressure side (13) to the evaporator (6) and the chiller (9) and the second valve outlet (22) of the first 3/2-way refrigerant valve with expansion function (8) is connected to the refrigerant collector (11).
  2. Refrigeration system and heat pump arrangement according to Claim 1 , characterized in that an air PTC (7) is arranged in an air conditioning unit (20) in addition to the heating condenser (2) or the water-cooled condenser (18) for heating the air for the vehicle cabin.
  3. Refrigeration system and heat pump arrangement according to Claim 1 or 2 , characterized in that the receiver (15) is designed as a refrigerant collector and refrigerant dryer at high pressure level of the refrigerant.
  4. Refrigeration system and heat pump arrangement according to one of the Claims 1 until 3 , characterized in that the shut-off valve (17) is designed as a solenoid valve.
  5. Refrigeration system and heat pump arrangement according to one of the Claims 1 until 4 , characterized in that the second 3/2-way refrigerant valve with expansion function (3) has a first valve outlet (21), a second valve outlet (22) and a valve inlet (23), wherein the valve inlet (23) is connected to the heating condenser (2) or the water-cooled condenser (18) and the first valve outlet (21) is connected to the receiver (15) and the check valve (16) and the second valve outlet (22) is connected to the ambient heat exchanger (4).
  6. Refrigeration system and heat pump arrangement according to one of the Claims 1 until 5 , characterized in that the first 3/2-way refrigerant valve with expansion function (8) has a first valve outlet (21), a second valve outlet (22) and a valve inlet (23), wherein the valve inlet (23) is connected to the compressor (1) on the high-pressure side and the first valve outlet (21) is connected to the ambient heat exchanger (4) and the second valve outlet (22) is connected to the refrigerant receiver (11).
  7. Method for operating a refrigeration and heat pump arrangement according to one of the Claims 1 until 6 for actively cooling the vehicle cabin and the battery in refrigeration system operation at ambient temperatures above 30 °C, characterized in that the refrigerant after the compressor (1) via the first 3/2-way The refrigerant flows through the refrigerant valve (8) into the ambient heat exchanger (4) and condenses. It then passes through the internal high-pressure side heat exchanger (12) and the check valve (16) into the receiver (15). A first refrigerant mass flow then flows to the refrigerant valve with expansion function (5), where it expands. In the evaporator (6), it absorbs heat from the air to cool the vehicle cabin and is directed via the internal low-pressure side heat exchanger (13) to the compressor (1). A further refrigerant mass flow is directed to the refrigerant valve with expansion function (10), where it expands. In the chiller (9), the refrigerant evaporates and cools a battery cooling circuit. A second refrigerant mass flow is directed via the refrigerant collector (11) to the suction side of the compressor (1).
  8. Method for operating a refrigeration and heat pump arrangement according to one of the Claims 1 until 6 for actively cooling the vehicle cabin in refrigeration system operation at ambient temperatures above 30 °C, characterized in that the refrigerant after the compressor (1) passes through the first 3/2-way refrigerant valve (8) into the ambient heat exchanger (4) and condenses, passes through the internal heat exchanger high-pressure side (12), the check valve (16) into the receiver (15), after which the refrigerant flows to the refrigerant valve with expansion function (5) and is expanded there and evaporates in the evaporator (6) by absorbing heat from the air to cool the vehicle cabin and is directed via the internal heat exchanger low-pressure side (13) to the compressor (1).
  9. Method for operating a refrigeration and heat pump arrangement according to one of the Claims 1 until 6 for actively cooling the battery in refrigeration system operation at ambient temperatures above 15 °C, characterized in that the refrigerant after the compressor (1) passes through the first 3/2-way refrigerant valve (8) into the ambient heat exchanger (4) and condenses, passes through the internal heat exchanger high-pressure side (12), the check valve (16) into the receiver (15), after which the refrigerant is directed to the refrigerant valve with expansion function (10) and is expanded there and evaporates in the chiller (9) and cools a battery cooling circuit, after which the refrigerant is directed via the refrigerant collector (11) to the suction side of the compressor (1).
  10. Method for operating a refrigeration and heat pump arrangement according to one of the Claims 1 until 6 for the reheat mode of the vehicle cabin in refrigeration system operation and for active cooling of the battery at ambient temperatures above 15 °C, characterized in that the refrigerant releases heat after the compressor (1) in the heating condenser (2) or in the water-cooled condenser (18), is subsequently expanded to a medium pressure level in the second 3/2-way refrigerant valve with expansion function (3) and releases heat in the ambient heat exchanger (4), is directed via the internal heat exchanger high-pressure side (12), the check valve (16) and the receiver (15) to the refrigerant valve with expansion function (5) and is expanded to a low pressure level, and that a refrigerant mass flow evaporates in the evaporator (6) absorbing heat from the air and is directed via the internal heat exchanger low-pressure side (13) to the compressor (1), and another refrigerant mass flow is directed to the refrigerant valve with expansion function (10) and expanded there, after which refrigerant in the chiller (9) evaporates and cools a battery cooling circuit and the refrigerant mass flow is directed via the refrigerant collector (11) to the suction side of the compressor (1).
  11. Method for operating a refrigeration and heat pump arrangement according to one of the Claims 1 until 6 for the reheat mode of the vehicle cabin in refrigeration system operation at ambient temperatures of more than 15 °C, characterized in that the refrigerant releases heat after the compressor (1) in the heating condenser (2) or in the water-cooled condenser (18), is subsequently expanded to a medium pressure level in the second 3/2-way refrigerant valve with expansion function (3) and is directed via the ambient heat exchanger (4), the internal heat exchanger high pressure side (12), the check valve (16) and the receiver (15) to the refrigerant valve with expansion function (5) and is expanded to a low pressure level and is evaporated in the evaporator (6) by absorbing heat from the air and is directed via the internal heat exchanger low pressure side (13) to the compressor (1).
  12. Method for operating a refrigeration and heat pump arrangement according to one of the Claims 1 until 6 for the reheat mode of the vehicle cabin in heat pump operation at ambient temperatures above 0 °C, characterized in that the refrigerant releases heat after the compressor (1) in the heating condenser (2) or in the water-cooled condenser (18), is subsequently directed and expanded via the second 3/2-way refrigerant valve (3) and via the receiver (15) to the refrigerant valve with expansion function (5), is subsequently evaporated in the evaporator (6) absorbing heat from the air and is directed via the internal heat exchanger low-pressure side (13) to the compressor (1), wherein the internal heat exchanger high-pressure side (12) is not permeated by refrigerant.
  13. Method for operating a refrigeration and heat pump arrangement according to one of the Claims 1 until 6 for the reheat mode of the vehicle cabin in heat pump operation and use of ambient heat at ambient temperatures above 0 °C, characterized in that the refrigerant releases heat after the compressor (1) in the heating condenser (2) or in the water-cooled condenser (18), is subsequently directed via the second 3/2-way refrigerant valve (3) to the receiver (15) and after the receiver (15) a first refrigerant mass flow is expanded in the refrigerant valve with expansion function (14) and absorbs heat in the ambient heat exchanger (4), is subsequently directed via the shut-off valve (17) in bypass to the first 3/2-way refrigerant valve (8) to the refrigerant collector (11) and a second refrigerant mass flow is expanded in the refrigerant valve with expansion function (5) and evaporates in the evaporator (6) absorbing heat from the air and is directed to the compressor (1).
  14. Method for operating a refrigeration and heat pump arrangement according to one of the Claims 1 until 6 for the reheat mode of the vehicle cabin in heat pump operation and use of vehicle waste heat at ambient temperatures above 0 °C, characterized in that the refrigerant releases heat after the compressor (1) in the heating condenser (2) or in the water-cooled condenser (18), is subsequently routed via the second 3/2-way refrigerant valve (3) and the receiver (15), and after the receiver (15) a first refrigerant mass flow is routed to the refrigerant valve with expansion function (5) and is expanded, and evaporates in the evaporator (6) absorbing heat from the air, and a second refrigerant mass flow after the receiver (15) is expanded in the refrigerant valve with expansion function (10) and absorbs heat in the chiller (9) and is subsequently routed via the refrigerant collector (11) to the compressor (1).
  15. Method for operating a refrigeration and heat pump arrangement according to one of the Claims 1 until 6 for the reheat mode of the vehicle cabin in heat pump operation and use of ambient heat and vehicle waste heat at ambient temperatures above 0 °C, characterized in that the refrigerant releases heat after the compressor (1) in the heating condenser (2) or in the water-cooled condenser (18), is subsequently routed via the second 3/2-way refrigerant valve (3) and the receiver (15), and after the receiver (15) a first refrigerant mass flow is routed to the refrigerant valve with expansion function (5) and expanded, and evaporates in the evaporator (6) absorbing heat from the air, and a second refrigerant mass flow after the receiver (15) is expanded in the refrigerant valve with expansion function (10) and absorbs heat in the chiller (9) and is subsequently routed via the refrigerant receiver (11) to the compressor (1), and a third refrigerant mass flow after the receiver (15) is expanded in the refrigerant valve with expansion function (10) and in the The ambient heat exchanger (4) absorbs heat and is subsequently routed via the shut-off valve (17) in the bypass to the first 3/2-way refrigerant valve (8) to the refrigerant collector (11) and via the refrigerant collector (11) to the compressor (1).
  16. Method for operating a refrigeration and heat pump arrangement according to one of the Claims 1 until 6 in heat pump operation and use of ambient heat at ambient temperatures higher than -30 °C, characterized in that the refrigerant releases heat after the compressor (1) in the heating condenser (2) or in the water-cooled condenser (18), is subsequently directed via the second 3/2-way refrigerant valve (3) to the receiver (15) and is expanded after the receiver (15) in the refrigerant valve with expansion function (14) and absorbs heat in the ambient heat exchanger (4) and is subsequently directed via the shut-off valve (17) in the bypass to the first 3/2-way refrigerant valve (8) to the refrigerant collector (11) and is directed via the refrigerant collector (11) to the compressor (1).
  17. Method for operating a refrigeration and heat pump arrangement according to one of the Claims 1 until 6 in heat pump operation and use of vehicle waste heat at ambient temperatures higher than -30 °C, characterized in that the refrigerant releases heat after the compressor (1) in the heating condenser (2) or in the water-cooled condenser (18), is subsequently directed via the second 3/2-way refrigerant valve (3) to the receiver (15) and is expanded after the receiver (15) in the refrigerant valve with expansion function (10), is evaporated in the chiller (9) and is directed via the refrigerant collector (11) to the compressor (1).
  18. Method for operating a refrigeration and heat pump arrangement according to one of the Claims 1 until 6 in heat pump operation and use of ambient heat and vehicle waste heat at ambient temperatures higher than -30 °C, characterized in that the refrigerant releases heat after the compressor (1) in the heating condenser (2) or in the water-cooled condenser (18), is subsequently directed via the second 3/2-way refrigerant valve (3) to the receiver (15) and after the receiver (15) a first refrigerant mass flow is expanded in the refrigerant valve with expansion function (14) and absorbs heat in the ambient heat exchanger (4) and subsequently via the shut-off valve (17) in the bypass to the first 3/2-way refrigerant valve (8) to the refrigerant collector (11) and via the refrigerant collector (11) to the compressor (1) and a second refrigerant mass partial flow is expanded in the refrigerant valve with expansion function (10), evaporated in the chiller (9) and via the refrigerant collector (11) to the compressor (1).
  19. Method for operating a refrigeration and heat pump arrangement according to one of the Claims 1 until 6 in heat pump operation and use of a hot gas circuit of the refrigerant at ambient temperatures higher than -30 °C, characterized in that the refrigerant releases heat after the compressor (1) in the heating condenser (2) or in the water-cooled condenser (18), is subsequently directed via the second 3/2-way refrigerant valve (3) to the receiver (15) and after the receiver (15) is directed to the refrigerant valve with expansion function (10) and is expanded, evaporated in the chiller (9) and directed via the refrigerant collector (11) to the compressor (1).
  20. Method for operating a refrigeration and heat pump arrangement according to one of the Claims 1 until 6 in defrosting operation at ambient temperatures higher than -30 °C, characterized in that the refrigerant after the compressor (1) passes through the first 3/2-way refrigerant valve (8) into the ambient heat exchanger (4) and condenses, passes through the check valve (16) into the receiver (15), after which the refrigerant is directed to the refrigerant valve with expansion function (10) and is expanded there and evaporates in the chiller (9) and cools a battery cooling circuit, after which the refrigerant is directed via the refrigerant collector (11) to the suction side of the compressor (1).

Description

The invention relates to a refrigeration system and heat pump arrangement for heating and cooling battery-powered vehicles. Furthermore, the invention relates to methods for operating the refrigeration system and heat pump arrangement in selected operating modes, wherein the refrigerant circuit comprises either the cooling or the heating of the cabin depending on the mode and thus represents a combined heat pump and refrigeration system. The application area of the invention lies in the field of electrically powered vehicles, which generally use high-voltage batteries (HV batteries) as energy storage devices for the energy supply of the vehicle's drive train. Other areas of application for the invention include vehicles with so-called plug-in hybrids, which produce only small amounts of waste heat and whose batteries are integrated into a thermal management system. An efficient heat supply for the vehicle, combined with optimal thermal management of the battery and the electric powertrain, plays an important role in this. Electric battery-powered vehicles generate relatively little waste heat, and therefore there is a regular need to efficiently generate heat for heating the vehicle cabin and to provide it in sufficient quantity and at an appropriate temperature level. Thermal management systems for battery electric vehicles must enable flexible operation across a wide range of operating conditions. The operation of the vehicle, and therefore of the thermal management system, is influenced by various factors, such as environmental and driving conditions, human comfort, and component operation, for example, the high-voltage battery (HV battery), the electric powertrain, and the control units. With these aspects in mind, a vehicle's thermal management system must enable comfort functions such as interior climate control within a desired temperature range while simultaneously ensuring safe vehicle operation. In particular, adequate defrosting or fogging of the windshield and cooling of the high-voltage battery at high ambient temperatures must be achieved. Modern thermal management systems for battery electric vehicles allow the integration of various heat sources and heat sinks via both the refrigerant circuit and the coolant circuit to enable efficient and dynamic operation of the heating and cooling system and to ensure situation-dependent thermal performance for cooling or heating for various applications. In the prior art, refrigerant circuits for refrigeration systems and heat pump circuits are known for this configuration, which are specifically tailored to battery-powered vehicles. From the DE 10 2019 109 796 A1 For example, a heat flow management device and a method for operating a heat flow management device are disclosed, which includes a refrigerant circuit and a powertrain coolant circuit as well as a heating circuit heat transfer fluid circuit. The DE 10 2016 100 971 A1 concerns a climate control system for a vehicle with a heat pump subsystem and from the DE 10 2008 062 176 A1 A device and a method for temperature control of electrical components of a motor vehicle are known. From the US 2019/0344640 A1 This results in a thermal management device for a vehicle, which includes a heat pump. The DE 10 2020 111 505 A1 relates to a heat pump arrangement for battery-powered vehicles and a method for operating a heat pump arrangement, wherein several chillers are required to couple the refrigerant circuit and the heat transfer circuit in order to utilize the waste heat of the vehicle. Furthermore, from the JP 2019- 206 215 A A vehicle air conditioning system is known. This system provides a vehicle air conditioning system in which, if the target cooling temperature differs between several cooled devices, the respective target cooling temperature can be easily achieved. It comprises a first heat transfer circuit in which a first heat transfer medium flows, absorbing heat emitted by a battery; a second heat transfer circuit in which a second heat transfer medium flows, absorbing heat emitted by an electric motor; and a first heat transfer heat exchanger, which, through heat exchange between a refrigerant flowing in a refrigerant circuit and the first heat transfer medium flowing in the first heat transfer circuit, causes the heat from the first heat transfer medium to be transferred to the first heat transfer circuit. ten heat transfer medium heat is transferred to the refrigerant, and a second heat transfer medium heat exchanger is connected to the refrigerant circuit on a downstream side of the first heat transfer medium heat exchanger in the refrigerant circuit and causes heat to be transferred from the second heat transfer medium to the first heat transfer medium through a heat exchange between the refrigerant flowing in the refrigerant circuit and the second heat transfer medium flowing in the second heat transfer medium circuit. Furthermore, the following are assumed to be true from the JP 2019-182