Electric vehicle thermal management integrated module

Abstract

The application belongs to the technical field of automobile thermal management, and relates to an electric vehicle thermal management integrated module, which comprises a six-way water valve, an expansion water kettle, a battery cooler, a gas-liquid separator, a refrigerant valve, a refrigerant temperature sensor, a refrigerant pressure sensor, a water side manifold and a refrigerant manifold; the refrigerant manifold is provided with a first refrigerant pipeline, a second refrigerant pipeline, a third refrigerant pipeline, a fourth refrigerant pipeline, a fifth refrigerant pipeline and a sixth refrigerant pipeline; the water side manifold comprises an upper plate, a middle plate and a lower plate, and the upper plate is provided with a battery water pump, an electric drive water pump and the six-way water valve on one side. The application connects the circuits of the battery, the electric drive and the passenger cabin by using a multi-pipeline valve to form an integrated large circulation circuit and realize fine energy management.

Description

Technical Field

[0001] This invention belongs to the field of automotive thermal management technology, specifically relating to an integrated thermal management module for electric vehicles. Background Technology

[0002] As the automotive industry moves towards electrification and intelligentization, the complexity of vehicle energy management is gradually increasing, and the requirements for automotive energy management systems are also rising. To more effectively meet the needs of electric vehicles, integrated thermal management systems have become a clear trend.

[0003] In the past, electric vehicles typically employed traditional decentralized thermal management systems. These systems are characterized by independent circuits for the battery, motor control, and air conditioning systems, each with its own independent temperature control and piping systems. However, this decentralized structure suffers from low energy efficiency and low integration. The dispersed layout, complex piping, numerous components, and high cost also contribute to this problem. Therefore, the technical problem this invention urgently aims to solve is whether an integrated thermal management module for electric vehicles can be provided that utilizes multiple pipes and valves to connect some or all circuits of the battery, motor control, and air conditioning systems, forming an integrated large-loop circuit for refined energy management. Summary of the Invention

[0004] In view of this, the present invention provides an integrated thermal management module for electric vehicles.

[0005] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows:

[0006] An integrated thermal management module for electric vehicles includes a six-way water valve, an expansion tank, a battery cooler, a gas-liquid separator, and a water-side manifold and a refrigerant manifold stacked together, refrigerant valves, a refrigerant temperature sensor, and a refrigerant pressure sensor.

[0007] The refrigerant manifold is equipped with a first refrigerant pipe, a second refrigerant pipe, a third refrigerant pipe, a fourth refrigerant pipe, a fifth refrigerant pipe, and a sixth refrigerant pipe; the inlet end of the second refrigerant pipe is connected to the outlet of the vehicle's HVAC component, and the outlet end of the first refrigerant pipe is connected to the inlet of the HVAC component via the gas-liquid separator and the compressor in sequence; the second refrigerant pipe is also connected to the inlet end of the outdoor heat exchanger via a first electronic expansion valve, and the outlet end of the outdoor heat exchanger is connected to the inlet end of the fifth refrigerant pipe;

[0008] The water-side manifold includes an upper plate, a middle plate, and a lower plate stacked together. A battery-powered water pump, an electric water pump, and the six-way water valve are installed on one side of the upper plate.

[0009] The refrigerant valves include a first solenoid valve, a second solenoid valve, a first electronic expansion valve, a second electronic expansion valve, a third electronic expansion valve, a first refrigerant check valve, and a second refrigerant check valve.

[0010] Furthermore, the inlet end of the second refrigerant pipe is connected to the outlet of the vehicle's HVAC components; the outlet end of the second refrigerant pipe is connected to the fourth refrigerant pipe via a first solenoid valve.

[0011] The outlet end of the fourth refrigerant pipe is in contact with an inlet port of the battery cooler, and a second electronic expansion valve is installed in series on the fourth refrigerant pipe.

[0012] The third refrigerant pipe is connected to the fourth refrigerant pipe before the liquid inlet of the second electronic expansion valve. The third electronic expansion valve is connected in series on the third refrigerant pipe, and the liquid outlet of the third refrigerant pipe is connected to the first refrigerant pipe.

[0013] The first refrigerant pipe is in contact with a liquid outlet port of the battery cooler, and the liquid outlet of the first refrigerant pipe is connected to the gas-liquid separator. The liquid outlet of the gas-liquid separator is connected to the liquid inlet of the HVAC component through the compressor.

[0014] Furthermore, the inlet end of the sixth refrigerant pipe is connected to the fifth refrigerant pipe, a second solenoid valve is installed on the sixth refrigerant pipe, and the inlet end of the gas-liquid separator is connected to the sixth refrigerant pipe; the middle position of the fifth refrigerant pipe is also connected to the third refrigerant pipe through a first refrigerant check valve.

[0015] Furthermore, the upper plate is provided with a second water-side pipe, a third water-side pipe, a fourth water-side pipe and a fifth water-side pipe; the lower plate is provided with a sixth water-side pipe and a seventh water-side pipe;

[0016] The inlet end of the second water-side pipe is the battery outlet, which is connected to the outlet end of the battery. The outlet end of the second water-side pipe is connected to the third valve port of the six-way water valve. The first valve port of the six-way water valve is connected to the inlet end of the fourth water-side pipe. The outlet end of the fourth water-side pipe is connected to the fifth water-side pipe via a battery water pump. The outlet end of the fifth water-side pipe is the heating inlet, which is connected to the heater. The other end of the heater is connected to the heating outlet installed on the middle plate.

[0017] The heating outlet of the middle plate is connected to the inlet end of the sixth water-side pipe of the lower plate. The outlet end of the sixth water-side pipe is connected to the seventh water-side pipe through the battery cooler. The outlet end of the seventh water-side pipe is connected to the inlet end of the third water-side pipe on the upper plate. The outlet end of the third water-side pipe is the battery inlet, and the battery inlet is connected to the inlet end of the battery. The third water-side pipe is also connected to the second valve port of the six-way water valve.

[0018] Furthermore, the upper plate is also provided with a first water-side pipe and an eleventh water-side pipe; the lower plate is also provided with an eighth water-side pipe, a ninth water-side pipe and a tenth water-side pipe.

[0019] The fourth valve port of the six-way water valve is connected to the inlet end of the first water-side pipe, and the outlet end of the first water-side pipe is connected to the eleventh water-side pipe through the electric water pump. The outlet end of the eleventh water-side pipe is the electric drive inlet, and the electric drive inlet is connected to the inlet end of the electric drive module.

[0020] The liquid outlet of the electric drive module is connected to the electric drive outlet, the electric drive outlet is the liquid inlet of the tenth water side pipe, and the liquid outlet of the tenth water side pipe is connected to the fifth valve port of the six-way water valve.

[0021] The liquid outlet of the electric drive module is also connected to the heat dissipation module. The liquid outlet of the heat dissipation module is connected to the heat dissipation outlet, which is the liquid inlet of the eighth water-side pipe. The eighth water-side pipe is connected to the ninth water-side pipe through an expansion tank. The liquid outlet of the ninth water-side pipe is connected to the sixth valve port of the six-way water valve.

[0022] Furthermore, a water temperature sensor is installed on the sixth water-side pipe; a refrigerant pressure sensor is installed at the liquid inlet end of the second refrigerant pipe; a refrigerant temperature sensor is installed on the fifth refrigerant pipe; and a refrigerant pressure and temperature sensor is installed on the gas-liquid separator.

[0023] Furthermore, a second refrigerant check valve is also installed on the sixth refrigerant pipeline.

[0024] The beneficial effects of this invention are as follows:

[0025] The thermal management integrated module described in this application can realize three thermal cycles: an electric drive cycle, a battery cycle, and a crew compartment cycle. Multiple pipes are connected using a six-way water valve, allowing the three relatively independent thermal cycles to circulate independently or in series, achieving global thermal management and significantly improving energy efficiency. By integrating the electric drive cycle, crew compartment thermal management cycle, and battery thermal cycle, effective utilization and transfer of thermal energy can be achieved, improving overall thermal management efficiency. The integrated module reduces the thermal energy transmission paths and conversion links, reducing energy loss and improving energy utilization. Through the regulation of the six-way water valve, the thermal energy distribution and flow of each cycle can be flexibly adjusted, achieving precise thermal management control and improving thermal management performance. Integrating multiple cycles together reduces the number of pipes, valves, and other components, simplifying the system structure and reducing manufacturing costs and maintenance complexity. The integrated module also reduces leakage and loss during thermal energy transmission. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the overall front view of the present invention.

[0027] Figure 2 This is a schematic diagram of the overall rear view of the present invention.

[0028] Figure 3 This is a schematic diagram of the six-way water valve of the present invention.

[0029] Figure 4 This is a schematic diagram of the refrigerant manifold of the present invention.

[0030] Figure 5 This is a front view of the water-side manifold of the present invention.

[0031] Figure 6 This is a schematic diagram of the back of the water-side manifold of the present invention.

[0032] Figure 7 This is a schematic diagram of the module connections of the present invention.

[0033] Figure 8 This is a frontal schematic diagram of the coolant flow direction in Mode 1 of the present invention.

[0034] Figure 9 This is a schematic diagram of the coolant flow direction from the back of Mode 1 of the present invention.

[0035] Figure 10 This is a frontal schematic diagram of the coolant flow direction in Mode 2 of the present invention.

[0036] Figure 11 This is a schematic diagram of the coolant flow direction from the back of Mode 2 of the present invention.

[0037] Figure 12 This is a frontal schematic diagram of the coolant flow direction in Mode 3 of the present invention.

[0038] Figure 13 This is a schematic diagram of the coolant flow direction from the back of Mode 3 of the present invention.

[0039] Figure 14 This is a frontal schematic diagram of the coolant flow direction in Mode 4 of the present invention.

[0040] Figure 15 This is a schematic diagram of the coolant flow direction from the back of Mode 4 of the present invention.

[0041] Figure 16 This is a frontal schematic diagram of the coolant flow direction in Mode 5 of the present invention.

[0042] Figure 17 This is a schematic diagram of the coolant flow direction from the back of Mode 5 of the present invention.

[0043] Figure 18 This is a frontal schematic diagram of the coolant flow direction in Mode Six of the present invention.

[0044] Figure 19 This is a schematic diagram of the coolant flow direction from the back of Mode Six of the present invention.

[0045] Figure 20 This is a schematic diagram of the water-side manifold of the present invention.

[0046] in Figure 8-19 All of these structures conceal the refrigerant manifold.

[0047] The attached diagram shows: 1: Six-way water valve, 2: Expansion tank, 3: Battery cooler, 4: Gas-liquid separator, 5: Water-side manifold, 6: Refrigerant manifold, 7: Upper plate, 8: Middle plate, 9: Lower plate, 10: Battery water pump, 11: Electric drive water pump, 12: First water-side pipe, 13: Second water-side pipe, 14: Third water-side pipe, 15: Fourth water-side pipe, 16: Fifth water-side pipe, 17: Sixth water-side pipe, 18: Seventh water-side pipe, 19: Eighth water-side pipe, 20: Ninth water-side pipe, 21: Tenth water-side pipe, 22: Eleventh water-side pipe, 23: Battery, 24: Battery outlet, 25: Heating inlet, 26: Heater, 27: Heating outlet, 28: Battery inlet, 29: Electric drive inlet, 30: Electric drive outlet. 31: Electric drive module; 32: Heat dissipation outlet; 33: Heat dissipation module; 34: First refrigerant pipe; 35: Second refrigerant pipe; 36: Third refrigerant pipe; 37: Fourth refrigerant pipe; 38: Fifth refrigerant pipe; 39: Sixth refrigerant pipe; 40: HAVC component; 41: Liquid inlet of outdoor heat exchanger; 42: Liquid outlet of outdoor heat exchanger; 43: First solenoid valve; 44: Second solenoid valve; 45: First electronic expansion valve; 46: Second electronic expansion valve; 47: Third electronic expansion valve; 48: First refrigerant check valve; 49: Second refrigerant check valve; 50: Water temperature sensor; 51: Refrigerant pressure sensor; 52: Refrigerant temperature sensor; 53: Refrigerant pressure and temperature sensor; 54: Outdoor heat exchanger; 55: Compressor. Detailed Implementation

[0048] To further illustrate the technical means and effects of the present invention in order to achieve the intended purpose, the following detailed description of the specific implementation methods, structures, features and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided below.

[0049] It should be noted that the terms "first," "second," etc., used in the specification and claims of this application are used to distinguish similar objects, rather than to describe a specific order or sequence. It should be understood that such terms can be used interchangeably where appropriate.

[0050] It should be noted that, in this application, unless otherwise stated, directional terms such as "upper," "lower," "top," and "bottom" are generally used in relation to the direction shown in the accompanying drawings, or in relation to the vertical, perpendicular, or gravitational direction of the component itself; similarly, for ease of understanding and description, "inner" and "outer" refer to the inner and outer contours of each component itself, but the above directional terms are not intended to limit the present invention.

[0051] like Figure 1-19As shown, an integrated thermal management module for an electric vehicle includes a six-way water valve 1, an expansion tank 2, a battery cooler 3, a gas-liquid separator 4, a water-side manifold 5 and a refrigerant manifold 6 stacked together, refrigerant valves, a refrigerant temperature sensor 52, and a refrigerant pressure sensor 51. This application uses the six-way water valve 1 to connect different pipes, thereby achieving different functions, including: temperature equalization, cooling, and heating of the battery 23; heat dissipation of the electric drive module 31; waste heat utilization of the battery 23 and the electric drive module 31; and cooling, heating, and ventilation of the passenger compartment.

[0052] The refrigerant valves include a first solenoid valve 43, a second solenoid valve 44, a first electronic expansion valve 45, a second electronic expansion valve 46, a third electronic expansion valve 47, a first refrigerant check valve 48, and a second refrigerant check valve 49.

[0053] The water-side manifold 5 includes an upper plate 7, a middle plate 8, and a lower plate 9 stacked together. A battery-powered water pump 10, an electric water pump 11, and the six-way water valve 1 are installed on one side of the upper plate 7.

[0054] To achieve temperature equalization, cooling, and heating of battery 23, the structure adopted in this invention is as follows:

[0055] The upper plate 7 is provided with a second water-side pipe 13, a third water-side pipe 14, a fourth water-side pipe 15 and a fifth water-side pipe 16; the lower plate 9 is provided with a sixth water-side pipe 17 and a seventh water-side pipe 18.

[0056] Battery outlet 24 is connected to the liquid outlet of battery 23. The liquid inlet of the second water-side pipe 13 is the battery outlet 24, and the liquid outlet of the second water-side pipe 13 is connected to the third valve port of the six-way water valve 1.

[0057] The first valve port of the six-way water valve 1 is connected to the inlet end of the fourth water-side pipe 15. The outlet end of the fourth water-side pipe 15 is connected to the fifth water-side pipe 16 through the battery water pump 10. The outlet end of the fifth water-side pipe 16 is the heating inlet 25. The heating inlet is connected to the heater 26. The other end of the heater 26 is connected to the heating outlet 27 installed on the middle plate 8.

[0058] The heating outlet 27 of the middle plate 8 is connected to the inlet end of the sixth water-side pipe 17 of the lower plate 9. The outlet end of the sixth water-side pipe 17 is connected to the seventh water-side pipe 18 through the battery cooler 3. The outlet end of the seventh water-side pipe 18 is connected to the inlet end of the third water-side pipe 14 on the upper plate 7. The outlet end of the third water-side pipe 14 is the battery inlet 28, which is connected to the inlet end of the battery 23. The third water-side pipe 14 is also connected to the second valve port of the six-way water valve 1.

[0059] To achieve heat dissipation or waste heat utilization of the electric drive module 31, the structure adopted in this invention is as follows:

[0060] The upper plate 7 is also provided with a first water-side pipe 12 and an eleventh water-side pipe 22; the lower plate 9 is also provided with an eighth water-side pipe 19, a ninth water-side pipe 20 and a tenth water-side pipe 21.

[0061] The fourth valve port of the six-way water valve 1 is connected to the inlet end of the first water-side pipe 12. The outlet end of the first water-side pipe 12 is connected to the eleventh water-side pipe 22 through the electric water pump 11. The outlet end of the eleventh water-side pipe 22 is the electric drive inlet 29, which is connected to the inlet end of the electric drive module 31.

[0062] The liquid outlet of the electric drive module 31 is connected to the electric drive outlet 30, which is the liquid inlet of the tenth water side pipe 21. The liquid outlet of the tenth water side pipe 21 is connected to the fifth valve port of the six-way water valve 1.

[0063] The liquid outlet of the electric drive module 31 is also connected to the heat dissipation module 33. The liquid outlet of the heat dissipation module 33 is connected to the heat dissipation outlet 32. The heat dissipation outlet 32 ​​is the liquid inlet of the eighth water-side pipe 19. The liquid outlet of the eighth water-side pipe 19 is connected to the expansion tank. The liquid outlet of the expansion tank is connected to the ninth water-side pipe 20. The liquid outlet of the ninth water-side pipe 20 is connected to the sixth valve port of the six-way water valve 1.

[0064] To achieve cooling, heating, or ventilation of the passenger compartment, the structure employed in this invention is as follows:

[0065] The refrigerant manifold 6 is provided with a first refrigerant pipe 34, a second refrigerant pipe 35, a third refrigerant pipe 36, a fourth refrigerant pipe 37, a fifth refrigerant pipe 38, and a sixth refrigerant pipe 39; the inlet end of the second refrigerant pipe 35 is connected to the outlet of the vehicle's HVAC component 40, and the outlet end of the first refrigerant pipe 34 is connected to the inlet of the HVAC component 40 in sequence through the gas-liquid separator 4 and the compressor; the second refrigerant pipe is connected to the inlet end 41 of the outdoor heat exchanger through a first electronic expansion valve, and the outlet end 42 of the outdoor heat exchanger is connected to the inlet end of the fifth refrigerant pipe 38.

[0066] The inlet end of the second refrigerant pipe 35 is connected to the outlet of the vehicle's HVAC component 40; the outlet end of the second refrigerant pipe 35 is connected to the fourth refrigerant pipe 37 via the first solenoid valve 43.

[0067] The outlet end of the fourth refrigerant pipe 37 is connected to an inlet port of the battery cooler 3. It should be noted that there is no physical contact between the fourth and first refrigerant pipes and their interfaces with the battery cooler; energy delivery is solely through the battery cooler. A second electronic expansion valve 46 is connected in series on the fourth refrigerant pipe 37.

[0068] The third refrigerant pipe 36 is connected to the fourth refrigerant pipe 37 before the liquid inlet of the second electronic expansion valve 46. The third electronic expansion valve 47 is connected in series on the third refrigerant pipe 36. The liquid outlet of the third refrigerant pipe 36 is connected to the first refrigerant pipe 34.

[0069] The first refrigerant pipe 34 is connected to a liquid outlet of the battery cooler 3, and the liquid outlet of the first refrigerant pipe 34 is connected to the gas-liquid separator 4. The liquid outlet of the gas-liquid separator 4 is connected to the liquid inlet of the HVAC component 40.

[0070] The second refrigerant pipe 35 is also connected to the expansion tank 2 via a first electronic expansion valve 45; the liquid outlet 42 of the outdoor heat exchanger is connected to the liquid inlet of the fifth refrigerant pipe 38, the liquid inlet of the sixth refrigerant pipe 39 is connected to the fifth refrigerant pipe 38, a second solenoid valve 44 is installed on the sixth refrigerant pipe 39, and the liquid inlet of the gas-liquid separator 4 is connected to the sixth refrigerant pipe 39; the fifth refrigerant pipe 38 is also connected to the third refrigerant pipe 36 via a first refrigerant check valve 48 at its middle position. A second refrigerant check valve 49 is also installed on the sixth refrigerant pipe 39.

[0071] In this invention, the following monitoring devices are also provided: a water temperature sensor 50 is installed on the sixth water-side pipe 17; a refrigerant pressure sensor 51 is installed at the liquid inlet end of the second refrigerant pipe 35; a refrigerant temperature sensor 52 is installed on the fifth refrigerant pipe 38; and a refrigerant pressure and temperature sensor 53 is installed on the gas-liquid separator 4.

[0072] like Figure 2 As shown, the six-way water valve 1 used in this invention has a previously disclosed structure, comprising nine end-face flow ports, numbered 1, 1, 2, 3, 4, 4, 4, 5, and 6. The two end-face flow ports numbered 1 are connected, and the three end-face flow ports numbered 4 are connected. End-face flow port 1 corresponds to the first valve port, end-face flow port 2 corresponds to the second valve port, end-face flow port 3 corresponds to the third valve port, end-face flow port 4 corresponds to the fourth valve port, end-face flow port 5 corresponds to the fifth valve port, and end-face flow port 6 corresponds to the sixth valve port.

[0073] The working mode and principle of the electric vehicle thermal management integrated module of the present invention are as follows.

[0074] Mode 1: Electric drive cooling, battery 23 temperature equalization, and crew compartment cooling. In this mode, the six-way water valve 1 operates as follows: flow through the end face ports numbered 3→1 and 6→4.

[0075] During electric drive cooling, the coolant flowing through the electric drive module 31 flows towards the cooling module 33. The outlet of the cooling module 33 is connected to the cooling outlet 32. Then, the coolant passes through the eighth water-side pipe 19, the expansion tank 2, and the ninth water-side pipe 20 in sequence to the sixth valve port of the six-way water valve 1. In this mode, the sixth valve port is connected to the fourth valve port. The coolant enters from the sixth valve port and flows out from the fourth valve port. It then passes through the first water-side pipe 12, the electric drive water pump 11, and the eleventh water-side pipe 22 in sequence, and then flows out from the electric drive inlet 29 to the electric drive module 31, thereby realizing the thermal circulation of the coolant on the electric drive module 31 and thus achieving the purpose of cooling the electric drive module 31. The cooling module 33 is responsible for cooling the coolant flowing through it.

[0076] When the battery 23 is at a constant temperature, the coolant flowing through the battery 23 passes sequentially through the battery outlet 24, the second water-side pipe 13, the third valve port of the six-way water valve 1, the first valve port of the six-way water valve 1, the fourth water-side pipe 15, the battery water pump 10, the fifth water-side pipe 16, and the heating inlet 25 before flowing to the heater 26. After passing through the heater 26, the coolant again passes through the heating inlet 25, the sixth water-side pipe 17, the battery cooler 3, the seventh water-side pipe 18, the third water-side pipe 14, and the battery inlet 28 before entering the battery 23. During this cycle, neither the battery cooler 3 nor the heater 26 is working. The coolant flowing through the battery 23 enters from the third valve port of the six-way water valve 1 and exits from the first valve port of the six-way water valve 1. After passing sequentially through the heater 26 and the battery cooler 3, the coolant is at a constant temperature before flowing back to the battery 23, thus keeping the battery 23 at a constant temperature.

[0077] When the passenger compartment is cooled, the refrigerant flowing from the built-in condenser of the HVAC component 40 enters through the liquid inlet of the second refrigerant pipe 35 and passes through the first electronic expansion valve 45, the liquid inlet 41 of the outdoor heat exchanger, and then condenses on the outdoor heat exchanger 54. It then flows sequentially through the liquid outlet 42 of the outdoor heat exchanger, the fifth refrigerant pipe 38, the first refrigerant check valve 48, the second electronic expansion valve 46, the HVAC system of the HVAC component 40, the gas-liquid separator 4, and the compressor 55, circulating back to the built-in evaporator of the HVAC component 40. The refrigerant flowing through the built-in evaporator lowers the temperature inside the passenger compartment, thus achieving cooling. During this process, the first electronic expansion valve 45, the first refrigerant check valve 48, and the second electronic expansion valve 46 are operational; the second solenoid valve 44 and the third electronic expansion valve 47 are closed.

[0078] Mode 2: Utilization of waste heat from electric drive, heating of battery 23, and ventilation of the crew compartment. In this mode, the six-way water valve 1 operates as follows: flow through the end face channels numbered 5→1 and 3→4.

[0079] In this mode, the utilization of waste heat from the electric drive and the equalization of battery 23 are within the same thermal management cycle. The coolant, carrying heat after flowing through the electric drive module 31, sequentially passes through the fifth and first ports of the six-way water valve 1, the battery water pump 10, the heater 26, and the battery cooler 3 before reaching the battery 23; during this process, the battery cooler 3 and the heater 26 are not operating. The coolant, after flowing through the battery 23, sequentially passes through the third and fourth ports of the six-way water valve 1, and the electric drive water pump 11 before entering the electric drive module 31. This coolant circulation achieves the thermal management cycle of utilizing waste heat from the electric drive and heating the battery 23.

[0080] When the crew compartment is ventilated, the first solenoid valve 43, the second solenoid valve 44, the first electronic expansion valve 45, the second electronic expansion valve 46, the third electronic expansion valve 47, the first refrigerant check valve 48, and the second refrigerant check valve 49 are all closed.

[0081] Mode 3: Electric drive cooling, battery 23 cooling and crew cabin cooling. In this mode, the connection mode of the six-way water valve 1 is: flow through the end face channels numbered 6→4 and 3→1.

[0082] At this time, the electric drive self-circulates, connecting the expansion tank and the heat dissipation module for cooling. The battery is connected to the battery cooler for further cooling.

[0083] The operating mode of the crew cabin cooling is the same as that in operating mode one, so it will not be described in detail.

[0084] Mode 4: Utilization of waste heat from electric drive, equalization of battery 23, and ventilation of the crew compartment. In this mode, the connection mode of the six-way water valve 1 is: flow through the end face channels of 5→1 and 2→4.

[0085] In this mode, only the battery water pump is activated in the battery circuit to average out the internal temperature of the battery and reduce the temperature difference. In this mode, the battery cooler 3, multiple electronic expansion valves, and compressor 55 are in the off state. The coolant flowing through the electric drive module 31 passes sequentially through the tenth water-side pipe 21, the fifth and first valve ports of the six-way water valve 1, the battery water pump 10, and the heater 26 to the battery cooler 3. After passing through the battery cooler 3, it passes sequentially through the seventh water-side pipe 18, the inlet end of the third water-side pipe 14, the second and fourth valve ports of the six-way water valve 1, and the electric drive water pump 11 before entering the electric drive module 31, thus completing the waste heat utilization of the electric drive module 31.

[0086] When the crew compartment is ventilated, the first solenoid valve 43, the second solenoid valve 44, the first electronic expansion valve 45, the second electronic expansion valve 46, the third electronic expansion valve 47, the first refrigerant check valve 48, and the second refrigerant check valve 49 are all closed.

[0087] Mode 5: Utilization of waste heat from electric drive, equalization of battery 23, and heating of the crew cabin. In this mode, the six-way water valve 1 operates in the following configuration: flow through the end faces of valves 2→1 and 5→4.

[0088] The electric drive operates on an independent circulation system. The coolant flowing through the electric drive module 31 passes sequentially through the fifth and fourth valve ports of the six-way water valve 1, and then flows back through the electric drive module 31 via the electric drive water pump 11. The coolant does not flow through the battery 23, where a uniform temperature setting is implemented.

[0089] In this embodiment, a heat pump heating mode is used for heating the passenger compartment. The heat circulation method is as follows: refrigerant flowing from the built-in condenser of the HVAC component 40 flows into the liquid inlet of the second refrigerant pipe 35 and passes through the first electronic expansion valve 45, the liquid inlet 41 of the outdoor heat exchanger, and then sequentially through the liquid outlet 42 of the outdoor heat exchanger, the fifth refrigerant pipe 38, the sixth refrigerant pipe 39, the second refrigerant check valve 49, the gas-liquid separator 4, the pressure and temperature sensor, and the compressor 55, circulating back to the built-in condenser of the HVAC component 40. After the refrigerant flows through the built-in condenser, the temperature inside the passenger compartment will rise, thereby achieving passenger compartment heating. During this process, the second refrigerant check valve, the first electronic expansion valve, and the second solenoid valve are working; the first refrigerant check valve, the first solenoid valve, the second electronic expansion valve, and the third electronic expansion valve are closed.

[0090] Mode 6: Electric drive not needed, battery 23 for heating and crew cabin heating. In this mode, the connection mode of the six-way water valve 1 is: flow through the end face channels of 3→1 and 5→4.

[0091] In this mode, the electric drive operates in an independent cycle. The coolant flowing through the electric drive module 31 passes sequentially through the fifth and fourth ports of the six-way water valve 1, and then flows back through the electric drive module 31 via the electric drive water pump 11. The battery 23 heating and the crew cabin heating are in the same heat cycle.

[0092] The coolant flowing out of the battery 23 passes through the third and first ports of the six-way water valve 1 in sequence. The heater 26 is activated, and the coolant flows through the heater 26 and is heated before circulating back to the battery, thereby heating the battery 23.

[0093] After passing through heater 26, the heated coolant flows to battery cooler 3. The refrigerant in battery cooler 3 evaporates and absorbs heat from the coolant, carrying the heat to gas-liquid separator 4 to participate in the subsequent refrigerant cycle. The heated refrigerant passes through compressor 55 and enters the built-in condenser of HVAC component 40 to heat the passenger compartment. The refrigerant flowing out of HVAC component 40 passes through first solenoid valve 43 and third electronic expansion valve 47 and continues to exchange heat with the heated coolant flowing in battery cooler 3, and then continues to complete the heat cycle for the next heating operation.

[0094] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. An integrated thermal management module for electric vehicles, comprising a six-way water valve, an expansion tank, a battery cooler, a gas-liquid separator, and a water-side manifold and a refrigerant manifold stacked together, refrigerant valves, a refrigerant temperature sensor, and a refrigerant pressure sensor, characterized in that: The refrigerant manifold is equipped with a first refrigerant pipe, a second refrigerant pipe, a third refrigerant pipe, a fourth refrigerant pipe, a fifth refrigerant pipe, and a sixth refrigerant pipe; the inlet end of the second refrigerant pipe is connected to the outlet of the vehicle's HVAC component, and the outlet end of the first refrigerant pipe is connected to the inlet of the HVAC component via the gas-liquid separator and the compressor in sequence; the second refrigerant pipe is also connected to the inlet end of the outdoor heat exchanger via a first electronic expansion valve, and the outlet end of the outdoor heat exchanger is connected to the inlet end of the fifth refrigerant pipe; The water-side manifold includes an upper plate, a middle plate, and a lower plate stacked together. A battery-powered water pump, an electric water pump, and the six-way water valve are installed on one side of the upper plate. The refrigerant valves include a first solenoid valve, a second solenoid valve, a first electronic expansion valve, a second electronic expansion valve, a third electronic expansion valve, a first refrigerant check valve, and a second refrigerant check valve.

2. The electric vehicle thermal management integrated module according to claim 1, characterized in that, The inlet end of the second refrigerant pipe is connected to the outlet of the vehicle's HVAC components; the outlet end of the second refrigerant pipe is connected to the fourth refrigerant pipe via a first solenoid valve. The outlet end of the fourth refrigerant pipe is in contact with an inlet port of the battery cooler, and a second electronic expansion valve is installed in series on the fourth refrigerant pipe. The third refrigerant pipe is connected to the fourth refrigerant pipe before the liquid inlet of the second electronic expansion valve. The third electronic expansion valve is connected in series on the third refrigerant pipe, and the liquid outlet of the third refrigerant pipe is connected to the first refrigerant pipe. The first refrigerant pipe is in contact with a liquid outlet port of the battery cooler, and the liquid outlet of the first refrigerant pipe is connected to the gas-liquid separator. The liquid outlet of the gas-liquid separator is connected to the liquid inlet of the HVAC component through the compressor.

3. An integrated thermal management module for electric vehicles according to claim 2, characterized in that, The inlet end of the sixth refrigerant pipe is connected to the fifth refrigerant pipe. A second solenoid valve is installed on the sixth refrigerant pipe. The inlet end of the gas-liquid separator is connected to the sixth refrigerant pipe. The middle position of the fifth refrigerant pipe is also connected to the third refrigerant pipe through a first refrigerant check valve.

4. An integrated thermal management module for electric vehicles according to claim 3, characterized in that, The upper plate is provided with a second water-side pipe, a third water-side pipe, a fourth water-side pipe and a fifth water-side pipe; the lower plate is provided with a sixth water-side pipe and a seventh water-side pipe; The inlet end of the second water-side pipe is the battery outlet, which is connected to the outlet end of the battery. The outlet end of the second water-side pipe is connected to the third valve port of the six-way water valve. The first valve port of the six-way water valve is connected to the inlet end of the fourth water-side pipe. The outlet end of the fourth water-side pipe is connected to the fifth water-side pipe via a battery water pump. The outlet end of the fifth water-side pipe is the heating inlet, which is connected to the heater. The other end of the heater is connected to the heating outlet installed on the middle plate. The heating outlet of the middle plate is connected to the inlet end of the sixth water-side pipe of the lower plate. The outlet end of the sixth water-side pipe is connected to the seventh water-side pipe through the battery cooler. The outlet end of the seventh water-side pipe is connected to the inlet end of the third water-side pipe on the upper plate. The outlet end of the third water-side pipe is the battery inlet, and the battery inlet is connected to the inlet end of the battery. The third water-side pipe is also connected to the second valve port of the six-way water valve.

5. An integrated thermal management module for electric vehicles according to claim 4, characterized in that, The upper plate is also provided with a first water-side pipe and an eleventh water-side pipe; the lower plate is also provided with an eighth water-side pipe, a ninth water-side pipe and a tenth water-side pipe. The fourth valve port of the six-way water valve is connected to the inlet end of the first water-side pipe, and the outlet end of the first water-side pipe is connected to the eleventh water-side pipe through the electric water pump. The outlet end of the eleventh water-side pipe is the electric drive inlet, and the electric drive inlet is connected to the inlet end of the electric drive module. The liquid outlet of the electric drive module is connected to the electric drive outlet, the electric drive outlet is the liquid inlet of the tenth water side pipe, and the liquid outlet of the tenth water side pipe is connected to the fifth valve port of the six-way water valve. The liquid outlet of the electric drive module is also connected to the heat dissipation module. The liquid outlet of the heat dissipation module is connected to the heat dissipation outlet, which is the liquid inlet of the eighth water-side pipe. The eighth water-side pipe is connected to the ninth water-side pipe through an expansion tank. The liquid outlet of the ninth water-side pipe is connected to the sixth valve port of the six-way water valve.

6. An integrated thermal management module for electric vehicles according to claim 5, characterized in that, A water temperature sensor is installed on the sixth water-side pipe; a refrigerant pressure sensor is installed at the liquid inlet end of the second refrigerant pipe; a refrigerant temperature sensor is installed on the fifth refrigerant pipe; and a refrigerant pressure and temperature sensor is installed on the gas-liquid separator.

7. An integrated thermal management module for electric vehicles according to claim 6, characterized in that, The sixth refrigerant pipeline is also equipped with the second refrigerant check valve.

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