A thermal management system integrated structure

Abstract

The present invention discloses a novel high-efficiency thermal management system integrated structure, which belongs to the technical field of vehicle thermal management systems, and comprises a water jacket and a top cover installed on the top of the water jacket, wherein a compressor is arranged inside the water jacket, and the compressor comprises a compressor suction chamber, a compressor exhaust chamber and a compressor cylinder body, the compressor suction chamber is connected with a chiller, and the compressor exhaust chamber is connected with a water-cooled condenser; the present invention can greatly reduce the noise of the thermal system compressor under high speed conditions, further improve the integration level, reduce the volume of the integrated module, and reduce the weight and cost at the same time; isolate the refrigerant circuit, and further reduce the risk hidden danger caused by the flammable refrigerant; utilize the heat exchange medium of the water jacket and the secondary circuit to wrap all the refrigerant side components such as the compressor and the heat exchanger, so as to realize the secondary isolation of the refrigerant, and at the same time make full use of the surface area of ​​the heat exchanger, and reduce the heat leakage of the compressor and the heat exchanger to the environment.

Description

Technical Field

[0001] The present invention belongs to the technical field of vehicle thermal management systems, and in particular relates to an integrated structure of a thermal management system. Background Art

[0002] With the popularity of electric and hybrid vehicles, the thermal management system of the whole vehicle is developing in the direction of integration. The current integrated module mainly integrates the refrigerant and water channels with related components. The main integrated components include valves, water cooling and refrigerators. Compared with the previous decentralized layout solution, this integrated improvement has greatly simplified the previous structural design. However, the above solution still faces many problems, the most important of which is that the overall volume is relatively large and the weight is heavy.

[0003] Especially for systems that require a secondary circuit, the amount of refrigerant filled is still large; and the current compressor noise is relatively large, especially at high speeds, the noise of the compressor will cause noise pollution, and is therefore criticized; if only relying on conventional compressor body structure for optimization, it is still very difficult to significantly reduce the noise, and the existing technology has already achieved the extreme; at the same time, the production cost of the integrated module is relatively high, especially the various refrigerant flow plates and pipelines therein.

[0004] To this end, the present invention proposes an integrated structure of a thermal management system. Summary of the invention

[0005] The purpose of the present invention is to propose a thermal management system integrated structure in order to solve the problem that the overall volume and weight of the current thermal management system integrated module are relatively large and heavy, and the noise of the compressor may cause noise pollution.

[0006] In order to achieve the above-mentioned objectives, the present invention adopts the following technical solutions: a thermal management system integrated structure, including a water jacket and a top cover installed on the top of the water jacket, a compressor is arranged inside the water jacket, the compressor has a compressor suction chamber, a compressor exhaust chamber and a compressor cylinder body, the compressor suction chamber is connected to a chiller, and the compressor exhaust chamber is connected to a water-cooled condenser.

[0007] As a further description of the above technical solution:

[0008] A first inlet and a first outlet are arranged on a side of the water jacket close to the chiller, and a second inlet and a second outlet are arranged on a side of the water jacket close to the water-cooled condenser.

[0009] As a further description of the above technical solution:

[0010] A first isolating member is vertically arranged inside the water jacket. The first isolating member is in sealing contact with the compressor to divide the inside of the water jacket into a first water jacket cavity and a second water jacket cavity.

[0011] As a further description of the above technical solution:

[0012] A second isolating member is horizontally arranged inside the water jacket, and the second isolating member includes a first dividing cavity wall and a second dividing cavity wall. The first dividing cavity wall divides the first water jacket cavity into an upper and lower first cavity and a second cavity. The second dividing cavity wall divides the second water jacket cavity into an upper and lower third cavity and a fourth cavity. The first inlet corresponds to the first cavity, the first outlet corresponds to the second cavity, the second inlet corresponds to the third cavity, and the second outlet corresponds to the fourth cavity.

[0013] As a further description of the above technical solution:

[0014] The first isolating member is in a U-shaped structure. A U-shaped groove is formed on the inner wall of the U-shaped structure, and a U-shaped sealing gasket is arranged in the U-shaped groove.

[0015] As a further description of the above technical solution:

[0016] The first isolating member is provided with a flow hole, and the first water jacket cavity and the second water jacket cavity are connected through the flow hole.

[0017] As a further description of the above technical solution:

[0018] A liquid storage tank and a refrigerant channel are installed on the compressor cylinder body, and the liquid storage tank is located inside the water jacket.

[0019] As a further description of the above technical solution:

[0020] A refrigerant interface is provided on the top of the top cover, and the refrigerant interface is connected to the liquid storage tank.

[0021] As a further description of the above technical solution:

[0022] A controller, an expansion valve, a pressure sensor and a temperature sensor are installed on the top of the top cover.

[0023] As a further description of the above technical solution:

[0024] At least one shock-absorbing pad is installed on the inner bottom wall of the water jacket, and the bottom of the compressor contacts the top of the shock-absorbing pad.

[0025] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are:

[0026] 1. The present invention can significantly reduce the noise of the thermal system compressor under high speed conditions.

[0027] 2. The present invention further improves the integration level, reduces the volume of the integrated module, and reduces the weight and cost.

[0028] 3. The present invention isolates the refrigerant circuit, further reducing the risk of hidden dangers caused by the flammable refrigerant.

[0029] 4. The present invention utilizes the water jacket and the heat exchange medium of the secondary circuit to wrap all refrigerant side components such as the compressor and the heat exchanger to achieve secondary isolation of the refrigerant, while fully utilizing the surface area of ​​the heat exchanger to reduce heat leakage from the compressor and the heat exchanger to the environment. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 It is a three-dimensional structural schematic diagram of a thermal management system integrated structure.

[0031] Figure 2 The schematic diagram is a structural diagram of a water jacket and a first isolation member in an integrated structure of a thermal management system.

[0032] Figure 3 The figure is a schematic diagram of the structure of a U-shaped groove of a first isolation member in a thermal management system integrated structure.

[0033] Figure 4 The present invention is a schematic structural diagram of a first isolating member and a second isolating member in an integrated structure of a thermal management system.

[0034] Figure 5 A top view of an integrated structure of a thermal management system.

[0035] Figure 6 for Figure 5 Cross-section view along the AA direction.

[0036] Figure 7 for Figure 5 Cross-sectional view along the BB direction.

[0037] Legend:

[0038] 1. Water jacket; 101. First inlet; 102. First outlet; 103. Second inlet; 104. Second outlet; 105. First water jacket cavity; 106. Second water jacket cavity; 2. Top cover; 3. First isolation member; 301. U-shaped groove; 302. U-shaped sealing gasket; 4. Second isolation member; 401. First partition cavity wall; 402. Second partition cavity wall; 5. Shock-absorbing pad; 6. Chiller; 7. Compressor suction cavity; 8. Compressor exhaust cavity; 9. Water-cooled condenser; 10. Controller; 11. Expansion valve; 12. Pressure sensor; 13. Temperature sensor; 14. Refrigerant interface; 15. Liquid storage tank. DETAILED DESCRIPTION

[0039] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0040] See also Figure 1-7 The present invention provides a technical solution: a thermal management system integrated structure, including a water jacket 1 and a top cover 2 installed on the top of the water jacket 1, a compressor is arranged inside the water jacket 1, the compressor has a compressor suction chamber 7, a compressor exhaust chamber 8 and a compressor cylinder body, the compressor suction chamber 7 is connected to a chiller 6, and the compressor exhaust chamber 8 is connected to a water-cooled condenser 9. Specifically, the compressor suction chamber 7 and the chiller 6, the compressor exhaust chamber 8 and the water-cooled condenser 9 are connected by threads or welding, so a refrigerant flow channel can be formed inside; it is also worth noting that the chiller 6 and the water-cooled condenser 9 are not limited to being placed at the two ends or sides or the upper / lower part of the compressor, and can be specifically arranged according to needs; it is also worth noting that the present invention can be expanded to a multi-heat exchanger solution on this basis.

[0041] In a specific embodiment of the present invention, Figure 1 ,like Figure 6 and Figure 7 As shown, a first inlet 101 and a first outlet 102 are provided on a side of the water jacket 1 close to the chiller 6 , and a second inlet 103 and a second outlet 104 are provided on a side of the water jacket 1 close to the water-cooled condenser 9 .

[0042] In a specific embodiment of the present invention, Figure 6 and Figure 7 As shown, a first isolating member 3 is vertically arranged inside the water jacket 1. The first isolating member 3 is in sealing contact with the compressor to divide the interior of the water jacket 1 into a first water jacket cavity 105 and a second water jacket cavity 106. Specifically, the compressor and the water jacket 1 can be sealed by means of rubber or the like. After sealing, the first water jacket cavity 105 and the second water jacket cavity 106 are formed together with the first isolating member 3. The heat exchange medium of the secondary cooling circuit can flow through the water jacket cavity. The heat exchange medium in the first water jacket cavity 105 can fully exchange heat with the chiller 6 and the compressor suction cavity 7. The heat exchange medium in the second water jacket cavity 106 can fully exchange heat with the water jacket 1 and the compressor exhaust cavity 8.

[0043] In a specific embodiment of the present invention, Figure 6 and Figure 7As shown, the water jacket 1 is horizontally provided with a second isolator 4, the second isolator 4 includes a first dividing cavity wall 401 and a second dividing cavity wall 402, the first dividing cavity wall 401 divides the first water jacket cavity 105 into an upper and lower first cavity and a second cavity, the second dividing cavity wall 402 divides the second water jacket cavity 106 into an upper and lower third cavity and a fourth cavity, the first inlet 101 corresponds to the first cavity, the first outlet 102 corresponds to the second cavity, the second inlet 103 corresponds to the third cavity, and the second outlet 104 corresponds to the fourth cavity. Specifically, the low temperature cooling The liquid enters the first cavity from the first inlet 101, and then enters the input end of chiller 6. After flowing through chiller 6, it flows out from the output end of chiller 6 to the second cavity, and finally flows out from the first outlet 102 to achieve heat exchange; the high-temperature coolant enters the third cavity from the second inlet 103, and then enters the input end of the water-cooled condenser 9. After flowing through the water-cooled condenser 9, it flows out from the output end of the water-cooled condenser 9 to the fourth cavity, and finally flows out from the second outlet 104 to achieve heat exchange, which can realize that the hot channel and the cold channel are not connected to each other.

[0044] Since the heat exchange medium in the first water jacket cavity 105 wraps chiller 6, it can fully exchange heat with the low-temperature refrigerant in chiller 6, thereby reducing the temperature of the heat exchange medium in the first water jacket cavity 105; a first dividing cavity wall 401 is provided in the first water jacket cavity 105, so that the heat exchange medium flows through chiller 6 more evenly, further improving the heat exchange efficiency.

[0045] Since the heat exchange medium in the second water jacket cavity 106 wraps the water-cooled condenser 9, it can fully exchange heat with the high-temperature refrigerant in the water-cooled condenser 9; an isolation device can be set in the second water jacket cavity 106 to make the heat exchange medium flow through the water-cooled condenser 9 more uniform, further improving the heat exchange efficiency.

[0046] In a specific embodiment of the present invention, Figure 4 As shown, the first isolating member 3 is in a U-shaped structure, a U-shaped groove 301 is opened on the U-shaped inner wall of the first isolating member 3, and a U-shaped sealing gasket 302 is arranged in the U-shaped groove 301 to achieve sealing.

[0047] In a specific embodiment of the present invention, a flow hole (not shown in the figure) is provided on the first isolating member 3, and the first water jacket cavity 105 and the second water jacket cavity 106 are connected through the flow hole. The number of the flow holes is single, two, three, four, etc. The flow hole is a channel for the heat exchange medium of the secondary circuit, which is used for heat exchange, so that a part of the low-temperature coolant on the left half and the high-temperature coolant on the right half will be mixed. In this solution, the low-temperature coolant can be heated by the high-temperature coolant at low temperature, so as to increase the compressor speed, thereby increasing the compressor motor power to generate heat.

[0048] In a specific embodiment of the present invention, Figure 6 and Figure 7 As shown, a liquid storage tank 15 and a refrigerant channel are installed on the compressor cylinder body, and the liquid storage tank 15 is located inside the water jacket 1.

[0049] In a specific embodiment of the present invention, Figure 1 As shown, a refrigerant interface 14 is provided on the top of the top cover 2 , and the refrigerant interface 14 is connected to the liquid storage tank 15 .

[0050] In a specific embodiment of the present invention, Figure 1 As shown, a controller 10, an expansion valve 11, a pressure sensor 12 and a temperature sensor 13 are installed on the top of the top cover 2. The controller 10 facilitates the control of the module.

[0051] In a specific embodiment of the present invention, Figure 1 As shown, at least one shock-absorbing pad 5 is installed on the inner bottom wall of the water jacket 1, and the bottom of the compressor is in contact with the top of the shock-absorbing pad 5. It is worth noting that the shock-absorbing pad 5 is a single-stage or two-stage shock-absorbing pad, which can greatly reduce the vibration transmitted from the compressor to the outside world. The vibration isolation scheme can be adjusted according to the NVH requirements of the scheme. It is preferred to provide four shock-absorbing pads 5, which are evenly distributed at the bottom of the compressor.

[0052] Working principle: the water-cooled condenser 9, the compressor exhaust chamber 8, the compressor suction chamber 7, and the chiller 6 are devices for realizing the refrigerant cooling and heating cycle. According to the reverse Carnot cycle principle, the refrigerant in the water-cooled condenser 9 is relatively high temperature, and the refrigerant in the chiller 6 is relatively low temperature; the low-temperature refrigerant circulating in the chiller 6 can be used to cool the heat exchange medium in the first water jacket cavity 105, and the high-temperature refrigerant of the water-cooled condenser can be used to heat the heat exchange medium in the second water jacket cavity 106.

[0053] Since the water-cooled condenser 9 and chiller 6 are integrated with the compressor, and the liquid storage, refrigerant channel, various valves and sensors are integrated with the compressor, the number of parts and components is reduced, and the assembly workload is reduced, thereby reducing the cost of the entire machine.

[0054] Since all refrigerant circuit components are directly installed on the compressor cylinder, the refrigerant circuit and the compressor cylinder are integrated, which greatly reduces the volume of the relevant refrigerant circuit system, thereby reducing the system refrigerant charge.

[0055] The main body or all of the compressor and related components are wrapped by the heat exchange medium water channel, which greatly reduces the noise transmitted to the outside world by the compressor vibration; at the same time, through single-stage or two-stage shock absorption, the vibration transmitted to the outside world by the compressor body is greatly reduced.

[0056] In the present invention, a cooling water exchange medium and a water jacket are added between the refrigerant circuit and the air, which further isolates the refrigerant and reduces the risk of leakage of some flammable and explosive refrigerants.

[0057] In the present invention, the outer shell surface of each heat exchanger and compressor becomes an available heat exchange surface area, thereby increasing the heat exchange performance and reducing the heat leakage of the environment.

[0058] Since the low-temperature heat exchange medium in the first water jacket cavity 105 is cooled, it can be passed to the battery and the passenger compartment of the whole vehicle, thereby cooling the battery and the passenger compartment, or passed to the motor and the environment to absorb heat, and then the refrigerant temperature in the water-cooled condenser 9 is increased through the reverse Carnot cycle principle; since the high-temperature heat exchange medium in the second water jacket cavity 106 is heated, it can be passed to the battery and the passenger compartment of the whole vehicle, thereby heating the battery and the passenger compartment, or passed to the environment to release heat, and then the refrigerant temperature in the chiller 6 is reduced through the reverse Carnot cycle principle. If the low-temperature heat exchange medium in the first water jacket cavity 105 is connected to the heated high-temperature heat exchange medium in the second water jacket cavity 106, the heat exchange medium in the second water jacket cavity 106 can be used to heat the heat exchange medium in the first water jacket cavity 105, thereby increasing the low pressure of the compressor during operation. As the low pressure of the compressor is increased, the compressor speed can be increased, thereby increasing the operating power of the compressor, and the battery and the passenger compartment can be directly heated by the operating power of the compressor at ultra-low temperatures, thereby reducing the use of external heating equipment such as PTC. Since the controller 10 can be installed on the top cover 2 and connected to the plates on the first water jacket cavity 105 or the second water jacket cavity 106, the heat exchange medium in the cavity can be used to take away the higher temperature energy in the controller, thereby thermally protecting the controller. In the present invention, a single, double, three or four cavities can be independently set in the water jacket 1 for a single heat exchanger, and the coolant medium channel is connected with the heat exchanger, and independent operation and other schemes are utilized to realize the use of coolant medium heat exchange to improve the operating temperature range and heating capacity of the compressor at low temperature, or realize the function of independent heating / cooling / independent operation of multiple heat exchangers of the module.

[0059] The above are only preferred specific implementation modes of the present invention, but the protection scope of the present invention is not limited thereto. Any technician familiar with the technical field can make equivalent replacements or changes according to the technical solutions and inventive concepts of the present invention within the technical scope disclosed by the present invention, which should be covered by the protection scope of the present invention.

Claims

1. A thermal management system integrated structure, comprising a water jacket (1) and a top cover (2) mounted on the top of the water jacket (1), characterized in that: A compressor is arranged inside the water jacket (1), the compressor comprising a compressor suction chamber (7), a compressor exhaust chamber (8) and a compressor cylinder body, the compressor suction chamber (7) is connected to a chiller (6), and the compressor exhaust chamber (8) is connected to a water-cooled condenser (9); A first inlet (101) and a first outlet (102) are provided on a side of the water jacket (1) close to the chiller (6), and a second inlet (103) and a second outlet (104) are provided on a side of the water jacket (1) close to the water-cooled condenser (9); A first isolating member (3) is vertically arranged inside the water jacket (1), and the first isolating member (3) is in sealing contact with the compressor to divide the interior of the water jacket (1) into a first water jacket cavity (105) and a second water jacket cavity (106); A second isolating member (4) is horizontally arranged inside the water jacket (1), the second isolating member (4) comprising a first dividing cavity wall (401) and a second dividing cavity wall (402), the first dividing cavity wall (401) dividing the first water jacket cavity (105) into an upper and lower first cavity and a second cavity, the second dividing cavity wall (402) dividing the second water jacket cavity (106) into an upper and lower third cavity and a fourth cavity, the first inlet (101) corresponding to the first cavity, the first outlet (102) corresponding to the second cavity, the second inlet (103) corresponding to the third cavity, and the second outlet (104) corresponding to the fourth cavity; The first isolating member (3) has a U-shaped structure, a U-shaped groove (301) is provided on the U-shaped inner wall of the first isolating member (3), and a U-shaped sealing gasket (302) is provided in the U-shaped groove (301); The first isolating member (3) is provided with a circulation hole, and the first water jacket cavity (105) and the second water jacket cavity (106) are connected via the circulation hole; The low-temperature coolant enters the first cavity from the first inlet (101), then enters the input end of the chiller (6), flows through the chiller (6), flows out from the output end of the chiller (6) to the second cavity, and finally flows out from the first outlet (102), thereby achieving heat exchange; the high-temperature coolant enters the third cavity from the second inlet (103), then enters the input end of the water-cooled condenser (9), flows through the water-cooled condenser (9), flows out from the output end of the water-cooled condenser (9) to the fourth cavity, and finally flows out from the second outlet (104), thereby achieving heat exchange.

2. A thermal management system integrated structure according to claim 1, characterized in that: A liquid storage tank (15) and a refrigerant channel are mounted on the compressor cylinder body, and the liquid storage tank (15) is located inside the water jacket (1).

3. A thermal management system integrated structure according to claim 2, characterized in that: A refrigerant interface (14) is provided on the top of the top cover (2), and the refrigerant interface (14) is connected to a liquid storage tank (15).

4. A thermal management system integrated structure according to claim 3, characterized in that: A controller (10), an expansion valve (11), a pressure sensor (12) and a temperature sensor (13) are installed on the top of the top cover (2).

5. A thermal management system integrated structure according to claim 4, characterized in that: At least one shock-absorbing pad (5) is installed on the inner bottom wall of the water jacket (1), and the bottom of the compressor is in contact with the top of the shock-absorbing pad (5).

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