In this Article we talk about Ford’s Propane Push: A Game-Changer for BEV Thermal Systems. Ford has declared R290 propane-based full-secondary loop heat pumps as the top contender for improving HVAC performance and charging efficiency in battery electric vehicles (BEVs). After rigorous testing, the automaker found these systems outperform traditional direct expansion (DX) setups, positioning R290 as a game-changing refrigerant for the future of electric mobility.
As BEVs continue to dominate the automotive landscape, one key challenge remains: managing the thermal systems to maximize driving range, especially in varying climates. Ford tested several thermal management configurations, including air-to-air DX and water-to-water semi-secondary loop systems, but the full-secondary loop emerged victorious.
This innovation comes as environmental regulations tighten. The updated EU F-gas Regulation and restrictions on PFAS are pushing automakers toward greener solutions, and R290 fits the bill perfectly. According to Angelo Patti, Product Development Engineer at Ford, propane’s thermal properties make it the best global option, provided safety concerns are addressed.
Speaking at the ATMOsphere MAC Summit 2024, Patti emphasized the limitations of current refrigerants and highlighted how R290’s boiling point aligns with the ideal heat pump range, offering a significant performance leap.
Collaborating with DENSO, Ford’s tests revealed R290-based full-secondary loop systems outperform those using R1234yf by 5% in heating and 29% in cooling. Additionally, propane’s ability to maintain battery temperature accelerates fast charging, all while reducing compressor speed and cutting down on greenhouse gases, thanks to its ultra-low global warming potential (GWP).
However, propane’s flammability is a challenge Ford is tackling. By reducing refrigerant charge and implementing leak-detection technologies, they aim to make R290 a viable, safe choice for BEVs. Ford is set to present its findings to the U.S. EPA and will start full-scale development by 2025.
With the potential to revolutionize BEV thermal systems, R290 could be the key to unlocking greater efficiency and sustainability in electric vehicles globally.