Coolant manifold for thermal management module

Abstract

The invention relates to a coolant manifold for a thermal management module. A coolant manifold for a thermal management module includes: a plurality of tie plates, wherein each tie plate includes a plurality of nodal holes; and a plurality of node tubes, each node tube including a first flow channel, each node tube being configured to be inserted into a corresponding node hole of the plurality of connecting plates such that the plurality of connecting plates connect the plurality of node tubes, and such that the first flow channels of the plurality of node tubes constitute a part of a netted fluid channel.

Description

Technical Field

[0001] The present invention relates to the field of vehicles. More specifically, the present invention relates to a coolant manifold for a thermal management module of a vehicle. Background Art

[0002] The vehicle's thermal management module controls and cools the vehicle to ensure that the vehicle's components and the cockpit are within a reasonable temperature range, thereby achieving fuel saving, comfort, and increased mileage. In new energy vehicles, integrated thermal management modules are a development trend. The thermal management module includes components such as coolant manifolds, coolers, and valves.

[0003] In the existing integrated thermal management module, the coolant manifold adopts a two-half structure. Specifically, the coolant manifold includes two parts. Each part is formed by casting or forging. Then, the two parts can be welded together. The flow channels in the coolant manifold thus formed constitute a mesh structure with nodes.

[0004] However, there are some obvious problems in the design of this coolant manifold, including long design and development cycle, high mold cost and equipment investment cost, high energy consumption in the production process, and low flexibility.

[0005] Therefore, there is a need for a coolant manifold for a thermal management module that can be manufactured at low cost. Summary of the invention

[0006] One object of the present invention is to provide a coolant manifold for a thermal management module that can be manufactured at low cost. Another object of the present invention is to provide a coolant manifold for a thermal management module that can simplify the manufacturing process. Another object of the present invention is to provide a coolant manifold for a thermal management module that can achieve better thermal insulation performance. Another object of the present invention is to provide a coolant manifold for a thermal management module that can improve flexibility.

[0007] One aspect of the present invention provides a coolant manifold for a thermal management module, comprising: a plurality of connecting plates, each of which includes a plurality of node holes; and a plurality of node tubes, each of which includes a first flow channel, wherein each node tube is configured to be inserted into a corresponding node hole of the plurality of connecting plates so that the plurality of connecting plates connect the plurality of node tubes, and so that the first flow channels of the plurality of node tubes constitute a part of a meshed fluid channel.

[0008] According to some embodiments of the present invention, the node tube and the connection plate are connected by brazing.

[0009] According to certain embodiments of the present invention, the coolant manifold further comprises a plurality of connecting tubes, each of which comprises a second flow channel, wherein the plurality of connecting tubes are configured to connect the plurality of node tubes into a mesh structure so that the first flow channels of the plurality of node tubes and the second flow channels of the plurality of connecting tubes constitute a meshed fluid channel.

[0010] According to some embodiments of the present invention, the coolant manifold includes two connection plates, and the two connection plates are respectively mounted on the mesh structure including the plurality of node tubes and the plurality of connection tubes from both axial sides of the node tube.

[0011] According to some embodiments of the present invention, the node pipe has a diameter greater than that of the connecting pipe, the node pipe further includes an engagement hole, and the end of the connecting pipe is configured to be inserted into the engagement hole of the node pipe to connect the connecting pipe to the node pipe.

[0012] According to certain embodiments of the present invention, each connecting plate further includes a groove, and the plurality of connecting plates are arranged in pairs, wherein the grooves of each pair of connecting plates are arranged opposite to each other, and the grooves of each pair of connecting plates are combined into a third flow channel when they are engaged with each other, and wherein the plurality of connecting plates are configured to connect the plurality of node tubes into a mesh structure so that the first flow channels of the plurality of node tubes and the third flow channels in the plurality of connecting plates constitute a mesh-like fluid channel.

[0013] According to some embodiments of the present invention, the connecting plate is formed by a stamping process.

[0014] According to some embodiments of the present invention, the node tube is connected to the node hole of the connection plate by interference fit.

[0015] According to some embodiments of the present invention, the node tube and the connection plate are respectively made of aluminum or an aluminum alloy.

[0016] According to some embodiments of the present invention, the node tube is cut from the mother tube and formed by machining.

[0017] In the coolant manifold according to the embodiment of the present invention, the node pipe can be inserted into the node hole of the connecting plate to connect different node pipes through the connecting plate, without the need to form the coolant manifold by casting or forging, thereby shortening the design and development cycle, reducing mold and equipment investment costs, reducing production energy consumption and improving manufacturing flexibility. The node pipe and the connecting plate can also be connected by brazing to improve the rigidity of the coolant manifold. The connecting plate can be used to connect the node pipes to improve the connection strength on the one hand, and can also be used as a tool to maintain the position of the connecting plate during the brazing process on the other hand. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 is a schematic diagram of a coolant manifold according to a first embodiment of the present invention.

[0019] Figure 2 is an exploded schematic diagram of a coolant manifold according to a first embodiment of the present invention.

[0020] Figure 3 Schematic diagram of a first mother pipe and a node pipe according to a first embodiment of the present invention.

[0021] Figure 4 Schematic diagram of a second mother pipe and a connecting pipe according to a first embodiment of the present invention.

[0022] Figure 5 is a schematic diagram of a coolant manifold according to a second embodiment of the present invention.

[0023] Figure 6 is an exploded schematic diagram of a coolant manifold according to a second embodiment of the present invention.

[0024] Figure 7 FIG. 4 is a partial cross-sectional schematic diagram of a coolant manifold according to a second embodiment of the present invention.

[0025] Figure 8 Schematic diagram of a first mother tube and a node tube according to a second embodiment of the present invention. DETAILED DESCRIPTION

[0026] Hereinafter, embodiments of the present invention are described with reference to the accompanying drawings. The following detailed description and the accompanying drawings are used to exemplarily illustrate the principles of the present invention, and the present invention is not limited to the preferred embodiments described. The scope of the present invention is defined by the claims. The present invention is now described in detail with reference to exemplary embodiments, and some embodiments are illustrated in the accompanying drawings. The following description is made with reference to the accompanying drawings, and unless otherwise indicated, the same reference numerals in different drawings represent the same or similar elements. The schemes described in the following exemplary embodiments do not represent all schemes of the present invention. On the contrary, these schemes are merely examples of systems and methods of various aspects of the present invention involved in the appended claims.

[0027] The present invention provides a coolant manifold and a thermal management module including the coolant manifold. The thermal management module and the coolant manifold according to the embodiments of the present invention can be installed in a vehicle, such as an internal combustion engine vehicle with an engine as a driving source, an electric vehicle or a fuel cell vehicle with an electric motor as a driving source, or a hybrid vehicle with both an electric motor and an internal combustion engine as driving sources. Below, exemplary embodiments of the present invention are described with reference to the accompanying drawings. It should be understood that only certain embodiments of the present invention are shown in the accompanying drawings, and the scope of the present invention should be determined according to the claims.

[0028] The thermal management module can utilize coolant to circulate in the coolant flow loop to manage the temperature of the engine / motor and other components in the vehicle. According to an embodiment of the present invention, the thermal management module includes a coolant manifold. The coolant manifold can allow coolant to flow inside it and is used to distribute the coolant to different components. The thermal management module may also include components such as a cooler and a valve.

[0029] According to some embodiments of the present invention, the coolant manifold includes a plurality of connection plates and a plurality of node tubes. Each connection plate includes a plurality of node holes. Each node hole is used to install a node tube. Each node tube includes a first flow channel. Each node tube is configured to be inserted into a corresponding node hole of a plurality of connection plates so that the plurality of connection plates connect the plurality of node tubes, and the first flow channels of the plurality of node tubes constitute a part of a meshed fluid channel.

[0030] Exemplary embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Figure 1 is a schematic diagram of a coolant manifold according to a first embodiment of the present invention. Figure 2 is an exploded schematic diagram of a coolant manifold according to a first embodiment of the present invention. In an exemplary embodiment, as Figure 1 As shown, the coolant manifold includes a plurality of connection plates 10 , a plurality of node tubes 20 , and a plurality of connection tubes 30 .

[0031] A first flow channel is formed in each node tube 20. In some embodiments, the node tube 20 can be made of aluminum or an aluminum alloy. In an exemplary embodiment, the node tube 20 has a substantially cylindrical shape. In some embodiments, the node tube 20 can be cut from a first mother tube with holes, and optionally can also be machined. Figure 3 Schematic diagram of a first mother tube and a node tube according to a first embodiment of the present invention. Figure 3 As shown, the node tube 20 may be cut from the first mother tube 200 and then machined.

[0032] A second flow channel is formed in each connecting pipe 30. In an exemplary embodiment, each connecting pipe 30 can connect two node pipes 20. In some embodiments, some node pipes 20 can be connected to two or more connecting pipes 30 respectively. In some embodiments, the connecting pipe 30 can be made of aluminum or an aluminum alloy. In some embodiments, the connecting pipe 30 has a generally cylindrical shape. In some embodiments, the connecting pipe 30 can be cut out from a second mother pipe with holes, and optionally can also be machined. Figure 4 Schematic diagram of the second mother pipe and the connecting pipe according to the first embodiment of the present invention. Figure 4 As shown, the connecting pipe 30 can be cut out from the second mother pipe 300 .

[0033] In some embodiments, the diameter of the node tube 20 is greater than the diameter of the connecting tube 30. In some embodiments, the node tube 20 may include an engagement hole. In this case, the end of the connecting tube 30 may be inserted into the engagement hole of the node tube 20 to connect the connecting tube 30 to the node tube 20. In some embodiments, the connecting tube 30 may be connected to the node tube 20, such as the engagement hole of the node tube 20, by an interference fit.

[0034] When the node tube 20 is connected to the connecting tube 30, the first flow channel in the node tube 20 and the second flow channel in the connecting tube 30 are in fluid communication. By connecting different node tubes 20 together using the connecting tube 30, the node tube 20 and the connecting tube 30 can form a mesh structure, and the first flow channel in the node tube 20 and the second flow channel in the connecting tube 30 can form a mesh of fluid channels.

[0035] The two connecting plates 10 are arranged spaced apart in the vertical direction. In this article, the "vertical direction" refers to the direction perpendicular to the plane where the connecting plates are located. In some embodiments, the connecting plates 10 can be made of aluminum or aluminum alloy. Each connecting plate 10 includes a plurality of node holes 11, such as Figure 2 Each node hole 11 is used to install a node tube 20, such as Figure 1 As shown. In some embodiments, the connecting plate 10 has a substantially flat shape. In an exemplary embodiment, the connecting plate 10 can be formed by stamping.

[0036] After the node tubes 20 and the connecting tubes 30 form a mesh structure, two connecting plates 10 can be installed on the mesh structure from both axial sides of the node tubes 20, such as Figure 2 As shown. Specifically, the node hole 11 of one connection plate 10 can be respectively installed to one axial end of the corresponding node tube 20, and the node hole 11 of another connection plate 10 can be respectively installed to the other axial end of the corresponding node tube 20. Thus, the connection plate 10, the node tube 20 and the connection tube 30 can form an assembly. In some embodiments, the node tube 20 can be connected to the node hole 11 of the connection plate 10 by interference fit.

[0037] According to some embodiments of the present invention, the connection plate 10 and the node tube 20 may be connected by brazing. In an exemplary embodiment, a composite layer may be provided on the outer surface of the connection plate 10 for brazing connection between the connection plate 10 and the node tube 20. After the node tube 20 is installed in the node hole 11 of the connection plate 10, a brazing process may be used to improve the connection strength between the connection plate 10 and the node tube 20. In an exemplary embodiment, the melting point temperature of the composite layer material is lower than the melting point temperature of the materials of the connection plate 10, the node tube 20 and the connection tube 30. Specifically, the assembly including the connection plate 10, the node tube 20 and the connection tube 30 may be placed in a brazing device for heating. The heating temperature is controlled to be higher than the melting point temperature of the composite layer material and lower than the melting point temperature of the materials of the connection plate 10, the node tube 20 and the connection tube 30, so that the composite layer melts into a liquid state while the connection plate 10, the node tube 20 and the connection tube 30 remain in a solid state. The molten composite layer enters the gap between the connection plate 10 and the node tube 20 by wetting and capillary action, thereby forming a metallurgical bond with the connection plate 10 and the node tube 20. The connection plate 10 can be used to connect the node tube 20 to improve the connection strength on the one hand, and can also be used as a tool to maintain the position of the connection plate 10 during the brazing process on the other hand.

[0038] In some embodiments, the node tube 20 and the connecting tube 30 may also be connected by brazing. After the connecting tube 30 is connected to the node tube 20 and different node tubes 20 are connected to each other, a brazing process may be used to improve the connection strength between the node tube 20 and the connecting tube 30.

[0039] The coolant manifold according to the above exemplary embodiment of the present invention can be manufactured by the manufacturing method of the coolant manifold according to some embodiments of the present invention. The manufacturing method of the coolant manifold according to some embodiments of the present invention will be described in detail below.

[0040] According to certain embodiments of the present invention, a method for manufacturing a coolant manifold includes the following steps: providing a plurality of node tubes 20, wherein a first flow channel is formed in each node tube 20; providing a plurality of connecting tubes 30, wherein a second flow channel is formed in each connecting tube 30; connecting the node tubes 20 using the connecting tubes 30 to form a mesh structure, and making the first flow channel in the node tubes 20 and the second flow channel in the connecting tubes 30 form a mesh of fluid channels; providing two connecting plates 10, wherein each connecting plate 10 includes a plurality of node holes 11; and installing the two connecting plates 10 to the mesh structure from both axial sides of the node tubes 20 to form an assembly.

[0041] In some embodiments, a composite layer is disposed on the outer surface of the connection plate 10. The method for manufacturing the coolant manifold further includes heating the assembly including the connection plate 10, the node tube 20 and the connection tube 30 to braze the connection plate 10 and the node tube 20 using the composite layer.

[0042] In some embodiments, the manufacturing method of the coolant manifold further includes: cutting a node tube 20 from a first mother tube 200 with a hole. In some embodiments, the manufacturing method of the coolant manifold further includes: cutting a connection tube 30 from a second mother tube 300 with a hole. In some embodiments, the node tube 20 includes a coupling hole, and the manufacturing method of the coolant manifold further includes: inserting an end of the connection tube 30 into the coupling hole of the node tube 20 to connect the connection tube 30 to the node tube 20. In some embodiments, the connection tube 30 is connected to the coupling hole of the node tube 20 by an interference fit. In some embodiments, the node tube 20 is connected to the node hole 11 of the connection plate 10 by an interference fit.

[0043] Other embodiments of the coolant manifold may be correspondingly applied to the method for manufacturing the coolant manifold according to the present invention. Please refer to the above description for details and will not be described in detail here.

[0044] It is described above that the coolant manifold includes two connection plates 10 and includes the connection pipe 30. However, the present invention is not limited thereto. Another exemplary embodiment of the present invention will be described in detail below with reference to the accompanying drawings. Figure 5 is a schematic diagram of a coolant manifold according to a second embodiment of the present invention. Figure 6 is an exploded schematic diagram of a coolant manifold according to a second embodiment of the present invention. Figure 7 is a partial cross-sectional schematic diagram of a coolant manifold according to some embodiments of the second present invention.

[0045] In an exemplary embodiment, if Figure 5 As shown, the coolant manifold includes a plurality of connection plates 10 and a plurality of node tubes 20 .

[0046] A first flow channel is formed in each node tube 20. In some embodiments, the node tube 20 can be made of aluminum or an aluminum alloy. In an exemplary embodiment, the node tube 20 has a substantially cylindrical shape. In some embodiments, the node tube 20 can be cut from a first mother tube with holes, and optionally can also be machined. Figure 8 Schematic diagram of a first mother tube and a node tube according to a second embodiment of the present invention. Figure 8 As shown, the node tube 20 may be cut from the first mother tube 200 and then machined.

[0047] In some embodiments, the connecting plate 10 may be made of aluminum or an aluminum alloy. Each connecting plate 10 includes a plurality of node holes 11. Each node hole 11 is used to install a node tube 20. In an exemplary embodiment, the connecting plate 10 further includes a groove 12. In an exemplary embodiment, the connecting plate 10 may be formed by stamping.

[0048] The four connecting plates 10 are arranged spaced apart in the vertical direction. In the exemplary embodiment below, four connecting plates 10A, 10B, 10C and 10D are used as examples. Figure 6 As shown. Figure 6 In the exemplary embodiment shown, the four connecting plates 10 are divided into two pairs, wherein the connecting plates 10A and 10B form a pair, and the connecting plates 10C and 10D form a pair. The grooves 12 of the connecting plates 10A and 10B are arranged to be opposite to each other. When the connecting plates 10A and 10B are engaged with each other, the grooves 12 of the connecting plates 10A and 10B are combined to form a third flow channel. The grooves 12 of the connecting plates 10C and 10D are arranged to be opposite to each other. When the connecting plates 10C and 10D are engaged with each other, the grooves 12 of the connecting plates 10C and 10D are combined to form a third flow channel.

[0049] In an exemplary embodiment, the node holes 11 of the connection plates 10A and 10B are arranged to face each other. When the connection plates 10A and 10B are engaged with each other, the node holes 11 of the connection plates 10A and 10B are communicated with each other. In an exemplary embodiment, the node holes 11 of the connection plates 10C and 10D are arranged to face each other. When the connection plates 10C and 10D are engaged with each other, the node holes 11 of the connection plates 10C and 10D are communicated with each other.

[0050] Two adjacent connection plates 10 may be connected to each other. In some embodiments, two adjacent connection plates 10 may be connected to each other by flanging and riveting. In some embodiments, after the connection plates 10 are connected to each other, the node tube 20 may be inserted into the node hole 11 of the connection plate 10 to connect the node tube 20 to the connection plate 10. In some embodiments, the node tube 20 may be connected to the node hole 11 of the connection plate 10 by interference fit.

[0051] When the connection plate 10 and the node tube 20 are connected, the first flow channel in the node tube 20 and the third flow channel in the connection plate 10 are in fluid communication. By connecting different node tubes 20 together using the connection plate 10, the connection plate 10 and the node tube 20 can form a mesh structure, and the first flow channel in the node tube 20 and the third flow channel in the connection plate 10 can form a mesh of fluid channels.

[0052] According to some embodiments of the present invention, the connection plate 10 and the node tube 20 may be connected by brazing. In an exemplary embodiment, a composite layer may be provided on the outer surface of the connection plate 10 for brazing connection between the connection plate 10 and the node tube 20. After the node tube 20 is installed in the node hole 11 of the connection plate 10, a brazing process may be used to improve the connection strength between the connection plate 10 and the node tube 20. In an exemplary embodiment, the melting point temperature of the composite layer material is lower than the melting point temperature of the materials of the connection plate 10 and the node tube 20. Specifically, the assembly including the connection plate 10 and the node tube 20 may be placed in a brazing device for heating. The heating temperature is controlled to be higher than the melting point temperature of the composite layer material and lower than the melting point temperature of the materials of the connection plate 10 and the node tube 20, so that the composite layer melts into a liquid state while the connection plate 10 and the node tube 20 remain in a solid state. The melted composite layer enters the gap between the connection plate 10 and the node tube 20 by, for example, wetting and capillary action, thereby forming a metallurgical bond with the connection plate 10 and the node tube 20, respectively.

[0053] In some embodiments, the connection plate 10 may be hollowed out. Specifically, except for the node holes 11 and the grooves 12, the connection plate 10 may only maintain necessary structural connections, while other parts may be hollowed out.

[0054] The coolant manifold according to the above exemplary embodiment of the present invention can be manufactured by the manufacturing method of the coolant manifold according to some embodiments of the present invention. The manufacturing method of the coolant manifold according to some embodiments of the present invention will be described in detail below.

[0055] According to certain embodiments of the present invention, a method for manufacturing a coolant manifold includes the following steps: providing a plurality of node tubes 20, wherein a first flow channel is formed in each node tube 20; providing a plurality of connecting plates 10, wherein each connecting plate 10 includes a plurality of node holes 11 and includes grooves 12; connecting the connecting plates 10 to each other so that the grooves 12 of different connecting plates 10 are combined into a third flow channel; inserting the node tubes 20 into the node holes 11 of the connecting plates 10 to form a mesh structure, and so that the first flow channel in the node tubes 20 and the third flow channel in the connecting plates 10 form a mesh-like fluid channel.

[0056] In some embodiments, a composite layer is disposed on the outer surface of the connection plate 10. The method for manufacturing the coolant manifold further includes heating the assembly including the connection plate 10 and the node tube 20 to braze the connection plate 10 and the node tube 20 using the composite layer.

[0057] In some embodiments, the manufacturing method of the coolant manifold further includes: cutting a node tube 20 from the first mother tube 200 with holes. In some embodiments, the node tube 20 is connected to the node hole 11 of the connection plate 10 by interference fit.

[0058] Other embodiments of the coolant manifold may be correspondingly applied to the method for manufacturing the coolant manifold according to the present invention. Please refer to the above description for details and will not be described in detail here.

[0059] Although the present invention has been described with reference to exemplary embodiments, it should be understood that the present invention is not limited to the configuration and method of the above-described embodiments. On the contrary, the present invention is intended to cover various modifications and equivalent configurations. In addition, although the various elements and method steps of the disclosed invention are shown in various exemplary combinations and configurations, other combinations including more or less elements or methods also fall within the scope of the present invention.

[0060] Reference numerals list

[0061] 10. Connecting plate;

[0062] 10A connection board;

[0063] 10B connecting plate;

[0064] 10C Connecting plate;

[0065] 10D connecting plate;

[0066] 11 node holes;

[0067] 12 grooves;

[0068] 20-node tube;

[0069] 30 connecting pipe;

[0070] 200 first mother tube;

[0071] 300 Second mother pipe.

Claims

1. A coolant manifold for a thermal management module, comprising: a plurality of connection plates, wherein each connection plate comprises a plurality of node holes; and a plurality of node pipes, wherein each node pipe comprises a first flow channel, Each node tube is configured to be inserted into a corresponding node hole of the plurality of connection plates, so that the plurality of connection plates connect the plurality of node tubes, and the first flow channels of the plurality of node tubes constitute a part of a mesh-like fluid channel.

2. The coolant manifold according to claim 1, wherein: The node tube and the connection plate are connected by brazing.

3. The coolant manifold according to claim 2, further comprising a plurality of connecting pipes, wherein each connecting pipe comprises a second flow channel, in, The plurality of connecting pipes are configured to connect the plurality of node pipes into a network structure, so that the first flow channels of the plurality of node pipes and the second flow channels of the plurality of connecting pipes form a network of fluid channels.

4. The coolant manifold according to claim 3, wherein: The coolant manifold includes two connection plates, and the two connection plates are respectively mounted on the mesh structure including the plurality of node tubes and the plurality of connection tubes from both axial sides of the node tube.

5. The coolant manifold according to claim 4, wherein: The node pipe has a diameter greater than that of the connecting pipe, the node pipe further includes an engaging hole, and an end of the connecting pipe is configured to be inserted into the engaging hole of the node pipe to connect the connecting pipe to the node pipe.

6. The coolant manifold according to claim 1, wherein: Each connecting plate further comprises a groove, and the connecting plates are arranged in pairs, The grooves of each pair of connecting plates are arranged to be opposite to each other, and the grooves of each pair of connecting plates are combined into a third flow channel when they are engaged with each other, and The plurality of connection plates are configured to connect the plurality of node tubes into a mesh structure, so that the first flow channels of the plurality of node tubes and the third flow channels in the plurality of connection plates form a mesh-like fluid channel.

7. The coolant manifold according to any one of claims 1 to 6, wherein: The connecting plate is formed by a stamping process.

8. The coolant manifold according to claim 7, wherein: The node tube is connected to the node hole of the connection plate by interference fit.

9. The coolant manifold according to claim 8, wherein: The node tube and the connection plate are respectively made of aluminum or aluminum alloy.

10. The coolant manifold according to claim 9, wherein: The node tube is cut from the mother tube and formed by machining.

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