Thermal management module

Abstract

The present application relates to a thermal management module for an electric vehicle, comprising a reservoir and a dispenser, in which the thermal management module consists of two half-shells, each comprising a dispenser half-shell and a reservoir half-shell as a single piece, in which the two half-shells are connected to each other.

Description

Technical Field

[0001] The invention relates to the technical field of thermal management elements of components of the powertrain and high-voltage system of a battery-powered vehicle (BEV). A thermal management system conducts energy from a heat source to a heat sink. The heat sink is, for example, a radiator in the front end of the vehicle, a chiller in a heat pump circuit or, under certain boundary conditions, a high-pressure reservoir. The overall goal is to use energy as efficiently as possible. A thermal management module for an electric vehicle generally comprises a distributor and an optional reservoir. The invention relates to such a thermal management module. Background Art

[0002] For example, a similar thermal management module is known from US 10,665,908 B2, which includes a distributor and a reservoir. The reservoir contains a coolant, and the distributor contains a pump, a valve and a fluid guiding device. Usually, the reservoir of the prior art is divided into two main parts in the horizontal direction and is closed by means of a welded cover as the upper main part. In addition, a typical reservoir of the prior art has a plurality of chambers for degassing the coolant separated by vertical walls. In addition, the reservoir according to the prior art can be mounted and sealed at the distributor, which contains a pump, a valve and a fluid line. In the above-mentioned US 10,665,908 B2, the distributor is, for example, integrated into the lower shell of the reservoir. The distributor is usually welded from two or more parts along one or more welds.

[0003] A thermal management module for an electric vehicle according to the above technical field comprises a distributor and a reservoir. The distributor comprises a pump, a valve and a fluid line. The distributor typically consists of two or more parts. The reservoir contains a coolant and a coolant level sensor and is usually divided horizontally and closed at the top by means of a welded cover.

[0004] The problem is that it is difficult to connect and seal the dispenser and the reservoir to each other, especially when the parts consist of different materials and thus have different thermal material properties and geometric tolerances. Due to the relative movement between the parts and the different thermal expansion properties during operation, a durable and effective sealing of the parts is difficult. Therefore, an improved mounting method for connecting a dispenser and a reservoir is necessary.

[0005] Typically, horizontal welds enable the reservoir to contain a plurality of vertical chambers in order to guide the fluid along a path from an inlet or an outlet and to ensure degassing of the fluid, which is one of the main functions of the reservoir. Vertical chambers can be produced with the aid of horizontal welds in only one direction.

[0006] Furthermore, a level sensor is installed in the reservoir in order to determine the level of the fluid. The level sensor typically comprises two pins which can be introduced into the reservoir from above and which, in the event of a tilting of the reservoir or loss of fluid, can emerge from the fluid, which causes a fault message. This can be avoided by providing an additional fluid volume, which, however, only delays it in the event of a loss of fluid. The amount of the additional fluid volume required to avoid a fault message in the event of a tilting of the reservoir increases with the increasing horizontal spacing between the two pins of the level sensor. Summary of the invention

[0007] Against this background, an object of the present invention is to solve the above-mentioned problems.

[0008] This object is achieved by a thermal management module according to claim 1. Preferred embodiments are described in the further claims.

[0009] According to the present invention, a thermal management module for an electric vehicle is provided, the thermal management module comprising a reservoir and a distributor. The thermal management module consists of two half shells, the two half shells respectively comprising a distributor half shell and a reservoir half shell as a single part, wherein the two half shells are connected to each other.

[0010] The half shells, each comprising a reservoir half shell and a distributor half shell, are designed to form a thermal management module by assembly and connection. The two half shells do not have to be of the same size, but can be of different sizes and shapes, as long as they are shaped complementary to each other so that they can be connected and sealed to each other in such a way that the two half shells form a thermal management module according to the invention.

[0011] The half shell is preferably made of plastics, more preferably made of thermoplastic or thermosetting plastic and by a molding process, such as injection molding. For this reason, the half shell is configured so that it can be demoulded along a unique demoulding direction thereby can realize manufacturing simply and cost-effectively.

[0012] The configuration of the half shells is advantageous in itself, since it allows simple and economically advantageous molding, for example in that a single demoulding direction is possible and thus a small number of production steps can be achieved. The number of components of the thermal management module and thus the complexity and manufacturing costs are reduced by the integrated design of the two distributor half shells and the reservoir half shell, which are each a single piece. In addition, the installation involves fewer work steps and the fastening and sealing between the distributor and the reservoir can be better ensured due to the small number of joints. Thus, on the one hand, a smaller number of components and installation steps are achieved and on the other hand, a fixed, geometrically defined and effectively fluid-tight connection between the reservoir and the distributor is formed, since the number of components and joints is minimized by the integrated design of the distributor half shell and the reservoir half shell.

[0013] The distributor of the thermal management module according to the invention preferably comprises at least one pump, a valve and a fluid line, respectively, which are designed to convey and direct cooling fluid into the cooling fluid circuit of the electric vehicle in order to ensure heat management and, if necessary, cooling management for optimal utilization or dissipation of heat in the components mentioned at the outset.

[0014] Preferably, the thermal management module is designed such that the two half shells are connected along a common connecting seam which lies in one plane or in any case has no steps. This structural configuration makes it possible to join the two half shells in a simple and efficient manner. Furthermore, the production of the half shells can also be carried out efficiently, for example because the injection molding tool is geometrically simpler than in the case of a stepped or freely formed connecting seam.

[0015] It is also preferred that the thermal management module is designed in such a way that the common connecting seam is arranged vertically in the installed state of the thermal management module.

[0016] By means of the structures for connecting the distributor to the rest of the cooling fluid circuit, which are common in the current technical field, the design of the distributor half shell and the reservoir half shell as a single piece can be realized particularly well, in particular by means of a vertically extending connecting seam. The thermal management module is usually designed so that the reservoir is at least partially arranged above the distributor in the installed state of the thermal management module. In contrast to the vertically extending connecting seam, the horizontally extending connecting seam does not enable the configuration of the distributor half shell and the reservoir half shell as a single piece in these cases and requires more parts. However, horizontally or obliquely extending connecting seams are also conceivable in other constructions of the thermal management system and other arrangements of other components in the installation space.

[0017] In this context, the vertical extension of the connecting seam means that the connecting seam has a substantially vertical orientation when the thermal management module is in the installed state in the vehicle. That is, the connecting seam in the installed state of the thermal management module is located substantially in a plane, which is arranged substantially vertically. The connecting seam does not have to be strictly vertical, i.e. oriented at an angle of 90° to the horizontal. Deviations from the angle that can achieve the functions and effects described here are also included in the invention.

[0018] In a preferred embodiment, the two half shells of the thermal management module are welded to each other. For example, friction welding, heat welding, hot mirror welding or infrared welding can be used as welding methods. In an advantageous embodiment of the thermal management module according to the invention, the joining method can achieve high efficiency during production, especially through a design with only one connecting seam or weld seam, and does not require any additional components such as other joining methods, so that the total number of parts and assembly steps remains low.

[0019] With regard to the manufacturability of the combined reservoir part and dispenser part, it is preferred that the reservoir as well as the dispenser have vertical weld seams with respect to the demoulding direction.

[0020] The welding process is simpler with only one welding direction. The dispenser and the reservoir are made in one part so that no additional fastening or sealing between these parts is required.

[0021] Preferably, the reservoir is substantially spherical in shape. This allows for a simple molding and demoulding process and optimizes the use of the installation space depending on the arrangement of other systems and components in the vehicle. Furthermore, the spherical shape is generally advantageous with regard to fluid guidance compared to, for example, a square reservoir, since the fluid does not accumulate in the corners, for example when the thermal management module is tilted, and is conveyed more efficiently to the outlet. Furthermore, in the case of a spherical shape of the reservoir, the fill level detection is more accurate and more reliable and the mechanical properties, such as strength, are generally better.

[0022] Also preferably, the reservoir comprises a reservoir inlet, a reservoir outlet and a plurality of horizontal walls. The horizontal walls are designed to guide the cooling fluid along a serpentine path from the reservoir inlet to the reservoir outlet.

[0023] One of the main functions of the reservoir is the degassing of the fluid. The degassing in the thermal management module according to the present disclosure is ensured by a plurality of horizontal inner walls which force the fluid to flow on a serpentine path from the inlet to the outlet of the reservoir. By the serpentine guidance of the path along which the cooling fluid flows from the reservoir inlet to the reservoir outlet, the distance travelled by the cooling fluid is extended, thereby improving the degassing efficiency of the cooling fluid.

[0024] Just like the reservoir itself, the horizontal walls of the reservoir are separate in the unassembled state. In this way, each horizontal wall has a first part in the first half shell and a second part in the second half shell. Through the complementary arrangement of these structures in the two half shells, the horizontal wall is finally formed by assembling the reservoir. Each horizontal wall can be continuous in that the first part is arranged in contact with the second part. The first part and the second part of each horizontal wall can be welded to each other along the contact surface in this case. This configuration improves the mechanical properties and especially the strength of the entire reservoir. Alternatively, the first part and the second part of each horizontal wall can also have a spacing preferably less than 3 mm between each other, which is advantageous in terms of effective degassing.

[0025] The plurality of horizontal walls are preferably arranged such that each horizontal wall is inclined at an angle relative to the horizontal plane and is inclined downwardly towards the center of the reservoir. The angle of the horizontal walls relative to the horizontal plane is respectively an acute angle and is preferably less than 50°, more preferably less than 30°. The inclination of the horizontal walls towards the center of the reservoir supports a regular outflow of the cooling fluid even when the entire thermal management module is slightly tilted. However, in the sense of clarity and understandability and in order to distinguish them from the vertically arranged walls of the prior art, they are referred to as horizontal walls hereinafter.

[0026] In a preferred embodiment, at least one horizontal wall has a drainage opening, which is designed to allow air to escape from the area below the horizontal wall into the area above the horizontal wall.

[0027] When the horizontal wall is inclined towards the center of the reservoir as described above, it is expected that during the degassing of the cooling fluid, air will collect below the horizontal wall. Through the drainage opening located at the highest point of the horizontal wall in the area of ​​the transition into the reservoir body, the air can escape into the upper area of ​​the reservoir. The efficiency of the degassing is thereby improved and the risk of air being sucked into the dispenser is reduced.

[0028] Independently of the features mentioned above and below, but in any combination therewith, the reservoir comprises a fluid level sensor comprising two fluid level sensor pins. The fluid level sensor is designed to detect whether the fluid level is below a determined minimum fluid level. The pins of the fluid level sensor are covered and insulated so that only the tips of the pins are exposed and conductive. The length of the exposed tips of the pins is preferably less than 5 mm, more preferably less than 3 mm. Thus, only the position of the tips of the pins is relevant for the detection of the cooling fluid level. In order to keep the required fluid level as low as possible, the fluid level sensor pins are essentially vertically stacked one on top of the other and extend essentially horizontally from at least one of the half shells in the direction of the center of the reservoir. The tip of the lower of the two level sensor pins can then be submerged at any time and the tip of the upper of the two level sensor pins can be submerged when the fluid level is above the minimum level. The spacing between the pins along the two horizontal axes can be practically zero, so that no additional coolant quantity is needed in order to keep the tips of the two pins submerged in all tilting conditions of the reservoir. In this way, reliable level detection is also guaranteed in the case of a tilt of the thermal management module. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.

[0030] Figure 1A A perspective view of a preferred embodiment of a thermal management module is shown.

[0031] Figure 1B A perspective view of another preferred embodiment of a thermal management module is shown.

[0032] Figure 2 A top view of an embodiment of a first half shell of a thermal management module is shown.

[0033] Figure 3 The first half of the thermal management module is shown Figure 2 A stereoscopic view of an embodiment of the present invention.

[0034] Figure 4 A top view of one embodiment of a second housing half of a thermal management module is shown.

[0035] Figure 5 The second half of the thermal management module is shown Figure 4 A stereoscopic view of an embodiment of the present invention.

[0036] Figure 6 Show Figure 1A A top view of an embodiment of the present invention.

[0037] Figure 7 Show Figure 2 and 3 Side view of an embodiment of a first half shell.

[0038] Figure 8 Show Figure 4 and 5 Side view of an embodiment of the second half shell.

[0039] Fig. 9 Shown in Figure 7 The embodiment shown in FIG. 1 is a fluid guide within a reservoir.

[0040] Fig.10 Show Fig. 9 A reservoir and air guidance within the reservoir.

[0041] Fig.11 Show Fig.10 An enlarged partial view of the storage in FIG.

[0042] Fig.12 Show Figure 2 , 3 and an embodiment of 7, wherein the reservoir is sloped, directs cooling fluid and includes a sensor pin of a fluid level sensor. DETAILED DESCRIPTION

[0043] Figure 1A A three-dimensional view of a preferred embodiment of the thermal management module 1 is shown. Figure 1AAs can be seen in the figure, the first half shell 10 is connected to the second half shell 20 along the connecting seam 30. The connecting seam extends vertically. The connected half shells 10, 20 together form a reservoir 100 and a distributor 200 that are basically spherical in shape in the illustrated embodiment. The distributor 200 is designed to obtain cooling fluid 300 from different areas of the cooling fluid circuit. Partial volumes of the cooling fluid 300 are stored in the reservoir 100 and can be directed to the distributor 200, so that, for example, dynamic effects can be compensated and controlled. In addition, the distributor 200 is designed to convey the cooling fluid 300 and guide it back to different areas of the cooling circuit in relation to the operating point. For this purpose, the distributor has a plurality of interfaces, which are used as inflow or outflow portions and through which the cooling fluid 300 can be conveyed to different components, such as a radiator, a battery or a powertrain component, according to needs and operating points, so as to ensure optimal utilization and conduction of heat. For this purpose, the distributor 200 includes one or more pumps and at least one valve. Cooling fluid 300 is supplied to reservoir 100 from a remaining, not shown, cooling fluid return flow via reservoir inlet 110 and is conducted from reservoir 100 via reservoir outlet 120 to distributor 200. Reservoir 100 comprises a refilling neck which is closed by a cover and via which cooling fluid 300 can be added to the cooling fluid circuit.

[0044] Figure 1B Show Figure 1A Another embodiment of the thermal management module 1. The embodiment shown is similar to the embodiment in Figure 1A The embodiment shown in FIG. 1 differs only in minor structural changes. Thus, Figure 1B A slightly modified arrangement of the cooling fluid inlet and the cooling fluid outlet is shown. In particular, the reservoir inlet 110 is arranged next to the refill neck in a vertical orientation.

[0045] Figure 2 The top view of one embodiment of the first half shell 10 of the thermal management module 1 is shown in a front view. The connecting seam 30 lies essentially in one plane. The first half shells of the reservoir 100 and of the dispenser 200 are designed integrally as one piece and are connected to one another.

[0046] Figure 3 The first half shell 10 of the thermal management module 1 is shown. Figure 2 In this representation, the cover of the refill neck of the reservoir 100 is removed. The first half shell of the reservoir 100 comprises the reservoir inlet 110 and has a horizontal wall 130 on the inside, which is not oriented strictly horizontally, but is slightly inclined towards the center of the reservoir 100. The first half shell of the dispenser 200 comprises a plurality of fluid lines, which are formed by a plurality of line walls.

[0047] The first half shell 10 is designed to be complementary to the second half shell 20 in the region of the connecting seam 30. Thus, the cavities open toward the connecting seam 30, such as the horizontal chamber of the reservoir 100, the reservoir outlet 120 or the fluid line of the distributor 200, are only completely and functionally formed by connecting the first half shell 10 to the second half shell 20.

[0048] Figure 4 and 5 Different views of an embodiment of the second half-shell 20 of the thermal management module 1 are shown.

[0049] The second half shell 20 is designed to be complementary to the first half shell 10 in the region of the connecting seam 30. Thus, the cavity open toward the connecting seam 30 is only completely and functionally formed by connecting the first half shell 10 to the second half shell 20.

[0050] Figure 6 Show Figure 1A The thermal management module 1 is formed by connecting a first half shell 10 and a second half shell 20 .

[0051] Figure 7 and 8 The first half shell 10 is shown Figure 2 and 3 and the second half shell 20 Figure 4 and 5 The connecting seam 30 and all internal structures of the two half shells 10, 20 are designed so that when the two half shells 10, 20 are joined together, the thermal management module 1 and all internal structures, such as the horizontal chamber of the reservoir 100, the reservoir outlet 120 or the fluid lines of the distributor 200 are completely and functionally configured.

[0052] Fig. 9 Shown in Figure 7 1. The embodiment shown in FIG. 1 shows a fluid guide F in the reservoir 100. A partial volume of the cooling fluid is delivered via the reservoir inlet 110 and guided into the interior of the reservoir 100. The partial volume then reaches the first horizontal wall 130 and is guided via the first horizontal wall to the horizontal wall 130 located below it. Subsequently, the cooling fluid follows the meandering path taken by the horizontal wall 130 until the reservoir outlet 120, so as to be guided from there to the distributor 200.

[0053] also, Fig. 9 A fluid level sensor pin 140 is shown. The tips of the pin 140 are vertically spaced apart and are substantially exactly stacked one above the other with two horizontal axes. Here, the conductive tip of the pin 140 is arranged on a vertical center axis in order to minimize the effect of the tilting of the thermal management module 1 on the required cooling fluid volume in the reservoir 100.

[0054] Fig.10 Show Fig. 9 The storage tank 100 and the air guide L in the storage tank 100. The air guide L follows a path through which the air or gas released by degassing the cooling fluid 300 is guided from the lower region of the storage tank 100 to the upper region. The path is in principle opposite to the path taken by the cooling fluid 300. Through the drainage opening 132 designed for this purpose at the highest point of the horizontal wall 130, the air or gas can flow past the cooling fluid 300 and escape into the upper region of the storage tank 100.

[0055] Fig.11 yes Fig.10 1 and shows a part of the air guide L and the air channel in the reservoir inlet 110. The air collected in the air channel in the reservoir inlet 110 can thus escape into the area of ​​the refill nozzle of the reservoir 100 and does not hinder the entry of the cooling fluid 300 through the reservoir inlet 110.

[0056] Fig.12 Show Figure 2 , 3 and 7, wherein the reservoir is inclined, guides the cooling fluid and comprises a sensor pin of a fluid level sensor. By vertically stacking the tips of the sensor pins one above the other and arranging the tip of the upper sensor pin in the center, both tips remain submerged even when the fluid level is more inclined.

[0057] Reference numerals list

[0058] 1 Thermal Management Module

[0059] 10,20 Half Shell

[0060] 30 Connection seam

[0061] 100 Storage

[0062] 110 Storage Entrance

[0063] 120 Storage outlet

[0064] 130 Horizontal Wall

[0065] 132 Drainage opening

[0066] 140 Fluid Level Sensor Pin

[0067] 200 Distributor

[0068] 300 Cooling fluid

[0069] F Fluid Guidance

[0070] L Air guide

Claims

1. A thermal management module (1) for an electric vehicle, the thermal management module comprising A reservoir (100) and a distributor (200), wherein the thermal management module (1) consists of two half shells (10, 20), each of which comprises a distributor half shell and a reservoir half shell as a single part, wherein the two half shells (10, 20) are connected to one another.

2. The thermal management module (1) according to claim 1, wherein the half shells (10, 20) are connected along a common connecting seam (30), which lies in one plane.

3. The thermal management module (1) according to claim 1 or 2, wherein the connecting seam (30) is arranged vertically in the installed state of the thermal management module (1).

4. The thermal management module (1) according to any one of claims 1 to 3, wherein the two half shells (10, 20) are welded to one another along the connecting seam (30).

5. The thermal management module (1) according to any one of claims 1 to 4, wherein the reservoir (100) is substantially spherically shaped.

6. A thermal management module (1) according to any one of claims 1 to 5, wherein the reservoir (100) comprises a reservoir inlet (110), a reservoir outlet (120) and a plurality of horizontal walls (130), wherein the horizontal walls are designed to guide the cooling fluid (300) along a serpentine path from the reservoir inlet (110) to the reservoir outlet (120).

7. The thermal management module (1) according to claim 6, wherein the plurality of horizontal walls (130) are arranged such that each horizontal wall (130) is inclined at an angle relative to a horizontal plane and is inclined downwardly toward the center of the reservoir (100).

8. The thermal management module (1) according to claim 7, wherein at least one horizontal wall (130) has a drainage opening (132), which is designed to allow air to escape from the area below the horizontal wall (130) to the area above the horizontal wall (130).

9. In particular, a thermal management module (1) according to any one of claims 1 to 8, wherein the reservoir (100) includes two fluid level sensor pins (140), which are designed to detect whether the fluid level is lower than a determined minimum fluid level, and wherein the fluid level sensor pins (140) are basically vertically stacked on top of each other and extend horizontally from at least one of the half shells (10, 20) toward the center of the reservoir (100).

Images