Thermal management module

Abstract

A thermal management module (110) for controlling a temperature of a battery pack in a vehicle is disclosed. The thermal management module (110) comprises: at least one fluid channel (112) for conducting a cooling fluid (122) through the thermal management module (110), where the fluid channel (112) comprises two or three plastic parts (124), where the fluid channel (112) comprises at least one inlet (114) and at least one outlet (116); at least one fluid pump (118) for driving a cooling fluid (122) to move through the fluid channel (112), where the fluid pump (118) is fixed to the fluid channel (112); at least one heating element (120) arranged at least partially within the fluid channel (112) such that the cooling fluid (122) can be heated by the heating element (120). Further, a module manufacturing method of manufacturing a thermal management module (110) is disclosed.

Description

Technical Field

[0001] The present invention relates to a thermal management module for controlling the temperature of a battery pack in a vehicle. In addition, the present invention relates to a module manufacturing method for manufacturing a thermal management module. The device and method according to the present invention can generally be applied in the field of power storage used in vehicles, such as the field of electrical energy and / or electrochemical energy storage in vehicles. In particular, the present invention can be applied in the field of electric vehicles, such as fuel cells, hybrid and / or electric vehicles, such as cars and / or trucks. However, other applications are feasible. Background Art

[0002] In order to manage and / or control the temperature of the battery pack in the vehicle, a thermal management module is usually used. Usually, the thermal management module includes a cooling device and / or a heating device to prevent the battery pack of the vehicle from overheating and / or overcooling.

[0003] CN 110429357 A describes an expansion tank, a battery thermal management system and a vehicle. The expansion tank includes a shell and a heater, wherein a liquid inlet and a liquid outlet are formed on the shell; a cavity for accommodating a coolant is formed in the shell; and the heater is arranged in the cavity for heating the coolant in the cavity.

[0004] CN 112397806 A describes a battery cooling plate, a power battery system and a new energy vehicle combined with a heating function. The battery cooling plate is attached to the battery module and includes a cover plate and a base plate, a heat dissipation channel is formed in the cover plate and / or the base plate, the inlet end and the outlet end of the heat dissipation channel are respectively connected to the fluid inlet pipe and the fluid outlet pipe fluid, and the heat dissipation channel is a plurality of columns of channels arranged in parallel. The battery cooling plate includes a heating element and cooling fins corresponding to the heating element in position, and the heating element is arranged to correspond to the area between the plurality of columns of channels.

[0005] US2016 / 020496 A1 describes a battery pack including a battery cell, a thermal interface material adjacent to the battery cell, and a heater element coupled to the thermal interface material. A method is also described, the method comprising: monitoring at least one temperature condition of the battery pack, the battery pack including the battery cell, the thermal interface material, and the heater element coupled to the thermal interface material; and regulating the battery cell using the heater element when the at least one temperature condition drops below a predetermined threshold.

[0006] Despite the advantages of known thermal management modules, several technical challenges remain. Thus, thermal management modules are typically scalable and comprise many individual components requiring a large amount of installation space, complicating both manufacturing and assembly and resulting in high costs.

[0007] It is therefore desirable to provide an apparatus and method that addresses the above-mentioned drawbacks of known apparatus and methods. In particular, a reasonably sized thermal management module will be proposed that allows for simple assembly and manufacture. Summary of the invention

[0008] This problem is solved by a thermal management module for controlling the temperature of a battery pack in a vehicle and a module manufacturing method for manufacturing a thermal management module having the features of the independent claims. Advantageous embodiments are listed in the dependent claims and throughout the description, which can be realized individually or in any arbitrary combination.

[0009] As used below, the terms "having", "including" or "comprising" or any of their arbitrary grammatical variations are used in a non-exclusive manner. Therefore, these terms can refer both to the absence of other features in the entity described in the context in addition to the features introduced by these terms, and to the presence of one or more other features. As an example, the expressions "A has B", "A includes B" and "A contains B" can refer both to the absence of other elements in A in addition to B (i.e., the presence of A solely and exclusively consisting of B), and to the presence of one or more other elements in entity A in addition to B, such as element C, element C and D or even other elements.

[0010] In addition, it should be noted that when introducing the corresponding features or elements, the terms "at least one", "one or more" or similar expressions indicating that the features or elements may appear one or more times will usually be used only once. In the following, in most cases, when referring to the corresponding features or elements, the expression "at least one" or "one or more" will not be repeated, despite the fact that the corresponding features or elements may appear one or more times.

[0011] Furthermore, as used below, the terms "preferably", "more preferably", "particularly", "more particularly", "specifically", "more specifically" or similar terms are used in conjunction with optional features without limiting the alternative possibilities. Therefore, the features introduced by these terms are optional features and are not intended to limit the scope of the claims in any way. As will be appreciated by those skilled in the art, the present invention may be carried out by the use of alternative features. Similarly, the features introduced by "in one embodiment of the invention" or similar expressions are intended to be optional features, without any limitation on alternative embodiments of the invention, without any limitation on the scope of the invention and without any limitation on the possibility of combining the features introduced in this manner with other optional or non-optional features of the invention.

[0012] In a first aspect of the invention, a thermal management module is proposed, which is used to control the temperature of a battery pack in a vehicle, in particular an electric vehicle. The thermal management module comprises at least one fluid channel, which is used to guide a cooling fluid through the thermal management module. The fluid channel comprises two or three plastic parts. The fluid channel comprises at least one inlet and at least one outlet. In addition, the thermal management module comprises at least one fluid pump, which is used to drive the cooling fluid to move through the fluid channel, wherein the fluid pump is fixed to the fluid channel, i.e., fixed to a protrusion of the fluid channel. In addition, the thermal management module comprises at least one heating element, which is at least partially arranged in the fluid channel so that the cooling fluid can be heated by the heating element.

[0013] The term "thermal management module" as used herein is a broad term and is given its ordinary and customary meaning to a person of ordinary skill in the art and is not limited to a special or customized meaning. The term may specifically, but not limited to, refer to any system configured to generate and / or establish a temperature within a predetermined operating range and / or working range in a battery pack of a vehicle. In particular, the thermal management module may be, or may include, a plurality of elements for adapting and / or maintaining a predetermined temperature by adding thermal energy to the battery pack or withdrawing thermal energy from the battery pack. To this end, the thermal management module may include at least one heating device and optionally at least one cooling device.

[0014] The term "fluid channel" as used herein is a broad term and is given its common and customary meaning to a person of ordinary skill in the art, and is not limited to a special or customized meaning. The term may specifically refer to, but is not limited to, a pipe and / or tube having a closed cross-section of any shape, and may be configured to guide a cooling fluid, i.e., provide guidance to the flow direction of the cooling fluid. The fluid channel may specifically be or may include at least one wall, such as an enclosure wall, which is used to continuously enclose an internal space through which a cooling fluid can flow from the inlet of the fluid channel to the outlet of the fluid channel. In particular, the fluid channel, such as a wall of the fluid channel, includes two or three plastic parts, and therefore may include at least one plastic material. As used herein, the term "plastic part" may specifically refer to any part of an element including at least one plastic material, such as one or more of a thermoplastic material and a thermosetting material. In particular, the plastic parts may be individual parts or objects that assemble the fluid channel. Therefore, the plastic parts may be configured to form a fluid channel by combination. As an example, the fluid channel may have combined the functions of a housing, such as an enclosure and / or a fixture, to provide an enclosed space for enclosing a cooling fluid while providing a support surface for other components of the thermal management module, such as at least one fluid pump and at least one heating element.

[0015] The term "cooling fluid" as used herein is a broad term and is given its ordinary and customary meaning to a person of ordinary skill in the art, and is not limited to a special or customized meaning. The term may specifically refer to but is not limited to any coolant, such as a fluid coolant. In particular, the cooling fluid is configured to remove heat and / or to conduct heat to a radiator. As an example, the cooling fluid may remove heat and / or dissipate heat in the form of thermal energy by increasing the temperature of the cooling fluid or by changing the state of aggregation of the cooling fluid, such as in the form of phase change enthalpy. The cooling fluid may be or may include at least one liquid, such as one or more of water, glycerol, ethylene glycol, ethanol, propylene glycol, and oil. Additionally or alternatively, the cooling fluid may be or may include at least one gaseous fluid, such as, for example, air.

[0016] In particular, the cooling fluid may be configured to cool the battery pack. However, the cooling effect may also be the opposite, i.e. allowing heating of the battery pack rather than cooling the battery pack. Thus, although the cooling fluid is primarily described in conjunction with its cooling purpose, the cooling fluid is also explicitly configured to heat the battery pack, i.e. increase the temperature of the battery pack, based on a comparison of the actual temperature of the battery pack with a preferred or predetermined operating and / or working temperature range of the battery pack.

[0017] As used herein, the term "fluid pump" is a broad term and is given its common and customary meaning for those of ordinary skill in the art, and is not limited to a special or customized meaning. The term may specifically refer to, but is not limited to, any device configured to move a fluid, such as a liquid and / or gas, particularly a cooling fluid, by a mechanical action that is generally converted from electrical energy to hydraulic energy. In particular, as used herein, a fluid pump may be a positive displacement pump or may include a positive displacement pump. As an example, a fluid pump may include at least one impeller and a housing in which the impeller may be positioned, so that by rotating the impeller in the housing, the fluid, i.e., the cooling fluid, may be moved. As an example, the housing of a fluid pump may be a portion of a fluid channel, such as at least a portion of an enclosure wall of a fluid channel.

[0018] The term "heating element" as used herein is a broad term and is given its common and customary meaning to a person of ordinary skill in the art, and is not limited to a special or customized meaning. The term may specifically refer to, but is not limited to, any system configured to provide heat and / or thermal energy to its surrounding material by increasing its own temperature. The heating element may, for example, be or may include an electric heating element configured to generate thermal energy by converting from electrical energy. Specifically, by directly or indirectly contacting the cooling fluid in the fluid channel, the heating element may be configured to transfer thermal energy to the cooling fluid, thereby, for example, heating the cooling fluid. In particular, the heating element may be at least partially arranged in the fluid channel so that the cooling fluid may be heated by the heating element.

[0019] The fluid channel may completely surround the heating element in at least one plane. In particular, the fluid channel may completely surround the heating element in at least two orthogonal planes. Thus, the heating element may be arranged completely or partially within the wall of the fluid channel, for example such that the heating element: protrudes from the wall of the fluid channel into the flow path of the cooling fluid, forms part of the wall of the fluid channel, or is arranged within the wall of the fluid channel. One or more.

[0020] Additionally or alternatively, the heating element may be arranged inside the fluid channel. Specifically, the heating element may be arranged inside the fluid channel so that the heating element is arranged in the flow path of the fluid in the fluid channel, i.e. the cooling fluid. As an example, the heating element may be arranged in the fluid channel so that the heating element is surrounded by the cooling fluid from at least three sides.

[0021] Additionally or alternatively, the heating element may protrude into the fluid channel such that the heating element penetrates a wall of the fluid channel. In particular, the heating element may penetrate at least one of two or three plastic parts of the fluid channel. Specifically, the heating element may protrude into the fluid channel such that at least a portion of the heating element is arranged outside the fluid channel, wherein at least one other portion of the heating element is arranged within the fluid channel, thereby protruding into the flow path of the cooling fluid.

[0022] The heating element may be or may include at least one resistive heating wire. Thus, as an example, the heating element may be or may include at least one metal wire, which, when energized, i.e. charged with an electric current, can convert electrical energy into heat energy due to its own resistance.

[0023] The thermal management module may also include at least one temperature sensor for measuring the temperature of the cooling fluid. The temperature sensor may be specifically arranged in the fluid channel. As an example, the temperature sensor may be arranged in a wall of the fluid channel and / or completely or partially arranged in the flow path of the cooling fluid in the fluid channel.

[0024] The thermal management module may also include at least one mixing valve for mixing cooling fluids from different parts of the fluid channel, i.e., cooling fluids with different temperatures. As an example, the fluid channel may include different parts, such as one or more side arms and / or feed lines. The mixing valve may be arranged in the flow path of the fluid channel and may be specifically fixed to the fluid channel, such as to the wall of the fluid channel. As an example, the mixing valve may be fixed to at least one of the two or three plastic parts of the fluid channel. The mixing valve may be configured to mix cooling fluids with different temperatures from, for example, different parts of the fluid channel. Therefore, by mixing cooling fluids with different temperatures, the mixing valve can set the temperature of the cooling fluid that reaches the outlet and can then flow toward the battery pack. The mixing valve may specifically be one or more of a two-way mixing valve and a multi-way mixing valve, in particular a three-way mixing valve.

[0025] The material of the first plastic part of the plastic parts may be different from the material of the second plastic part of the plastic parts. In particular, the material of the first plastic part of the two or three plastic parts may be different from the material of the second plastic part of the two or three plastic parts. For example, at least two of the two or three plastic parts may have different materials. In particular, the two or three shells are made of the same material so that they can be joined by welding. However, alternatively, the material of the first plastic part of the plastic parts may be the same as the material of the second plastic part of the plastic parts, for example, the materials of the first plastic part and the second plastic part may be consistent with each other. In particular, the material of the first plastic part of the two or three plastic parts may be the same as the material of the second plastic part of the two or three plastic parts. In particular, all plastic parts may be made of the same material. As an example, there may be only one material for all shell parts.

[0026] At least one of the plastic parts of the fluid channel may comprise a plastic material selected from the group comprising: a thermoplastic material, like polypropylene (PP) and / or polyamide (PA); a thermosetting material.

[0027] In another aspect of the invention, a module manufacturing method for manufacturing a thermal management module is proposed. The module manufacturing method, also referred to as method, comprises the following steps. The steps can be performed in the order given. Nevertheless, a different order is also possible. The method may include additional steps that are not mentioned. It is also possible to repeatedly perform one or more or all of the method steps. Furthermore, two or more of the method steps may be performed simultaneously or in a temporally overlapping manner.

[0028] The module manufacturing method comprises the following steps:

[0029] a) Producing two or three plastic parts for the fluid channels during injection molding;

[0030] b) providing at least one fluid pump and arranging the fluid pump on one of the plastic components;

[0031] c) providing at least one heating element and arranging the heating element on one of the plastic parts;

[0032] d) Joining two or three plastic parts in one or more welding processes, thereby creating a fluid channel.

[0033] As an example, in step b), at least a part of a fluid pump, such as an impeller, may be provided. In particular, the housing of the fluid pump may be a part of a fluid channel, such as at least a part of an enclosure wall of the fluid channel. Thus, in step b), instead of providing a complete fluid pump, a fluid pump without a housing may be provided, so that by arranging a part of the fluid pump without a housing on a plastic component, the fluid channel produced by joining the plastic components in step d) may serve as the housing of the fluid pump.

[0034] In addition, before executing step d), the method may further include:

[0035] e) Providing at least one temperature sensor and arranging the temperature sensor on one of the plastic components.

[0036] Additionally or alternatively, before performing step d), the method may further comprise:

[0037] f) Providing at least one mixing valve, in particular one or more of a two-way mixing valve and a three-way mixing valve, and arranging the mixing valve on one of the plastic components.

[0038] As an example, the module manufacturing method may be configured for manufacturing a thermal management module as described herein.Therefore, for possible definitions and selections, reference may be made to the description of the thermal management module as provided above or as further outlined below.

[0039] The proposed device and method offer a number of advantages over known devices and methods of similar type. In particular, the device and method according to the present application may, for example, due to its provision, allow a more efficient cooling and / or heating of the battery pack.

[0040] Furthermore, the proposed device and method may reduce the complexity of assembly and manufacturing. Specifically, the proposed thermal management module may have a reduced number of components compared to known devices. In particular, the proposed thermal management module and manufacturing method may allow for fewer individual parts, for example, the fluid channel comprises only two or three plastic parts. This may specifically contribute to reducing manufacturing costs and assembly complexity. For example, by reducing the number of joints and / or boundary surfaces, i.e. when assembling components to form a fluid channel, compared to known devices and methods, it contributes to reducing manufacturing costs and assembly complexity.

[0041] In summary and without excluding other possible embodiments, the following embodiments may be envisaged:

[0042] Embodiment 1: A thermal management module for controlling the temperature of a battery pack in a vehicle, particularly an electric vehicle, the thermal management module comprising:

[0043] at least one fluid channel for directing a cooling fluid through the thermal management module, wherein the fluid channel comprises two or three plastic components, wherein the fluid channel comprises at least one inlet and at least one outlet;

[0044] at least one fluid pump for driving the cooling fluid to move through the fluid channel, wherein the fluid pump is fixed to the fluid channel, i.e., fixed to a protrusion of the fluid channel;

[0045] At least one heating element is arranged at least partially within the fluid channel such that the cooling fluid can be heated by the heating element.

[0046] Embodiment 2: The thermal management module according to the preceding embodiment, wherein the fluid channel completely surrounds the heating element in at least one plane, in particular in at least two orthogonal planes.

[0047] Embodiment 3: The thermal management module of any of the preceding embodiments, wherein the heating element is arranged inside the fluid channel such that the heating element is arranged within a flow path of the cooling fluid in the fluid channel.

[0048] Embodiment 4: The thermal management module according to any of embodiments 1 and 2, wherein the heating element protrudes into the fluid channel such that the heating element penetrates a wall of the fluid channel, ie, penetrates one of the two or three plastic components.

[0049] Embodiment 5: The thermal management module of any of the preceding embodiments, wherein the heating element comprises at least one resistive heating wire.

[0050] Embodiment 6: The thermal management module according to any of the preceding embodiments, further comprising at least one temperature sensor for measuring the temperature of the cooling fluid, wherein the temperature sensor is arranged within the fluid channel.

[0051] Embodiment 7: The thermal management module according to any one of the preceding embodiments further includes at least one mixing valve, which is used to mix cooling fluids from different parts of the fluid channel, that is, cooling fluids with different temperatures, wherein the mixing valve is arranged in the flow path of the fluid channel and fixed to the fluid channel.

[0052] Embodiment 8: The thermal management module according to the above embodiment, wherein the mixing valve is one or more of a two-way mixing valve and a multi-way mixing valve, in particular a three-way mixing valve.

[0053] Embodiment 9: The thermal management module of any of the preceding embodiments, wherein a material of a first one of the plastic components is consistent with a material of a second one of the plastic components.

[0054] Embodiment 10: A thermal management module according to any of the preceding embodiments, wherein at least one of the plastic components of the fluid channel comprises a plastic material selected from the group consisting of: thermoplastic materials, such as polypropylene (PP) and / or polyamide (PA); thermosetting materials.

[0055] Embodiment 11: A module manufacturing method for manufacturing a thermal management module, the method comprising:

[0056] a) Producing two or three plastic parts for the fluid channels during injection molding;

[0057] b) providing at least one fluid pump and arranging the fluid pump on one of the plastic components;

[0058] c) providing at least one heating element and arranging the heating element on one of the plastic parts;

[0059] d) Joining two or three plastic parts in one or more welding processes, thereby creating a fluid channel.

[0060] Embodiment 12: The module manufacturing method according to the above embodiment, wherein before performing step d), the method further comprises:

[0061] e) Providing at least one temperature sensor and arranging the temperature sensor on one of the plastic components.

[0062] Embodiment 13: The module manufacturing method according to any one of the preceding embodiments relating to the module manufacturing method, wherein before performing step d), the method further comprises:

[0063] f) Providing at least one mixing valve, in particular one or more of a two-way mixing valve and a three-way mixing valve, and arranging the mixing valve on one of the plastic components.

[0064] Embodiment 14: The module manufacturing method according to any one of the preceding embodiments relating to the module manufacturing method, wherein the module manufacturing method is configured to manufacture a thermal management module according to any one of the preceding embodiments relating to the thermal management module. BRIEF DESCRIPTION OF THE DRAWINGS

[0065] Other optional features and embodiments will be disclosed in more detail in the subsequent description of the embodiments, preferably in combination with the dependent claims. Wherein, as will be appreciated by those skilled in the art, the corresponding optional features can be implemented in a separate manner and in any arbitrary feasible combination. The scope of the present invention is not limited by the preferred embodiments. Embodiments are schematically depicted in the drawings. Wherein, the same reference numerals in these figures refer to the same or functionally similar elements.

[0066] In the figure:

[0067] Figure 1 and Figure 2 Different embodiments of thermal management modules are shown in schematic top plan views;

[0068] Figure 3 An embodiment of a thermal management module is shown in schematic side view;

[0069] Figures 4a to 4c shows in perspective view an embodiment of a thermal management module during different stages of a method of manufacturing the module; and

[0070] Figure 5 and Figure 6 Different flow charts of the module manufacturing method are shown. DETAILED DESCRIPTION

[0071] exist Figure 1 and Figure 2, schematic top plan views of different embodiments of a thermal management module 110 are illustrated. The thermal management module 110 is configured for controlling the temperature of a battery pack in a vehicle and includes at least one fluid channel 112 having an inlet 114 and an outlet 116, at least one fluid pump 118, and at least one heating element 120. The fluid pump 118 is configured to drive a cooling fluid 122 through the fluid channel 112 and is fixed to the fluid channel 112. The heating element 120 is at least partially disposed within the fluid channel 112 so that the cooling fluid 122 can be heated by the heating element 120. Figure 1 The arrows in indicate the direction in which the cooling fluid 122 flows into the thermal management module 110 through the inlet 114 and out of the thermal management module 110 through the outlet 116. In particular, the cooling fluid 122 may be configured to flow toward the battery pack after leaving the thermal management module 110, thereby affecting the temperature of the battery pack, i.e., controlling the temperature of the battery pack.

[0072] The fluid channel 112 is configured to direct a cooling fluid 122 through the thermal management module 110 and includes two or three plastic components 124. As an example, the fluid channel 112 can be formed by joining the plastic components 124 together, such as by bonding. The fluid channel 112 can include different portions, such as one or more side arms 126 and / or a feed line 128. For example, when flowing through the fluid channel 112, the flow of the cooling fluid 122 can be divided into different portions of the fluid channel 112, such as the side arms 126, and can flow together at a junction, at which the side arms 126 of the fluid channel 112 can be joined together again before reaching the outlet 116. This setting is Figure 1 Alternatively, Figure 2 As exemplarily illustrated in FIG. 1 , the fluid channel 112 may include a plurality of inlets 114 such that the cooling fluid 122 may enter the thermal management module 110 through more than one feed line 128 included by the fluid channel 112 . Figure 2 In, with Figure 1 In contrast to the selected illustration, the fluid channel 112 and parts of the fluid channel, namely the feed line 128, are illustrated by simple lines in order to provide a better overview.

[0073] The thermal management module 110 may also include at least one mixing valve 130 for mixing the cooling fluid 122 from different portions of the fluid channel 112. The mixing valve 130 may be arranged in the flow path of the fluid channel 112 and may be fixed to the fluid channel 112. In particular, the cooling fluid from different portions of the fluid channel 112 may have different temperatures. As an example, the cooling fluid from Figure 1 The lower side arm 126 or Figure 2The cooling fluid 122 in the feed line 128 on the right side of the embodiment may have a larger cooling capacity than that in the portion of the fluid passage 112. Figure 1 and Figure 2 The horizontally illustrated heating element 120 heats the cooling fluid 122 at a lower temperature. The mixing valve 130 can set the temperature of the cooling fluid 122 reaching the outlet 116 by mixing the cooling fluid 122 from different parts of the fluid channel 112. Additionally or alternatively, the mixing valve 130 can be configured to mix the cooling fluid 122 having different flow rates from different parts of the fluid channel 112, thereby setting the rate at which the cooling fluid 122 flows through the fluid channel 112. The thermal management module 110 may include a plurality of mixing valves 130.

[0074] Additionally or alternatively, the thermal management module 110 may include a plurality of fluid pumps, for example, for controlling the speed at which the cooling fluid 122 flows through the fluid channel 112. Furthermore, additionally or alternatively, the thermal management module 110 may include a plurality of heating elements 120 for setting the temperature of the cooling fluid 122 reaching the outlet 116. Furthermore, additionally or alternatively, the thermal management module 110 may include at least one temperature sensor 132 for measuring the temperature of the cooling fluid 122. The temperature sensor 132 may be disposed within the fluid channel 112.

[0075] exist Figure 3 , a schematic side view of an embodiment of the thermal management module 110 is illustrated. The fluid channel 112 includes two or three plastic components 124, wherein, as an example, at least one of the plastic components 124 may include a plurality of protrusions and / or recesses to accommodate one or more of the heating element 120 and / or the fluid pump 118. Other protrusions and / or recesses may be present on the plastic component 124 for accommodating other parts of the thermal management module 110, such as, for example, one or more mixing valves 130 and / or a temperature sensor 132.

[0076] The heating element 120 may be at least partially disposed within the fluid channel 112. Thus, the heating element 120 may be disposed within the flow path of the cooling fluid 122 in the fluid channel 112, such as Figure 1 and Figure 3 Alternatively, the heating element 120 may be arranged to protrude into the fluid channel 112 so that the heating element 120 penetrates the wall of the fluid channel 112, such as Figure 4b and Figure 4c In particular, the heating element 120 may penetrate one of the two or three plastic parts 124 of the fluid channel 112 .

[0077] Figures 4a to 4c An embodiment of a thermal management module 110 during different stages of a module manufacturing method is illustrated in a perspective view. In particular, the thermal management module 110 may include a fluid channel 112, which includes two plastic parts 124, a carrier part 134 and a cover part 136. As an example, one or both of the carrier part 134 and the cover part 136 may include at least one fluid pump protrusion 138, such as a protrusion for the fluid pump 118, i.e., a protrusion for an impeller of the fluid pump 118. In addition, at least one of the carrier part 134 and the cover part 136 may include at least one heating element recess 140, through which the heating element 120 may protrude into the fluid channel 112. In addition, one or both of the carrier part 134 and the cover part 136 may include at least one sensor recess 142 and / or at least one valve recess 144 for accommodating at least one of the temperature sensor 132 and the mixing valve 130.

[0078] Figure 5 and Figure 6 Different flow charts of a module manufacturing method for manufacturing a thermal management module 110 are illustrated. The method comprises the following steps:

[0079] a) (indicated by reference numeral 146) producing two or three plastic parts 124 for the fluid channel 112 during an injection molding process;

[0080] b) (indicated by reference numeral 148 ) providing at least one fluid pump 118 and arranging the fluid pump 118 on one of the plastic components 124 ;

[0081] c) (indicated by reference numeral 150 ) providing at least one heating element 120 and arranging the heating element 120 on one of the plastic components 124 ;

[0082] d) (indicated by reference numeral 152) joining two or three plastic components 124 in one or more welding processes, thereby creating the fluid channel 112.

[0083] Before performing step d), the method may further include one or more of the following steps:

[0084] e) (indicated by reference numeral 154 ) providing at least one temperature sensor 132 and arranging the temperature sensor 132 on one of the plastic components 124 .

[0085] f) (indicated by reference numeral 156 ) at least one mixing valve 130 , in particular one or more of a two-way mixing valve and a three-way mixing valve, is provided and the mixing valve 130 is arranged on one of the plastic components 124 .

[0086] As an example, Figure 4a A first phase of the module manufacturing method after performing step a) 146 can be illustrated exemplarily. Figure 4b The second phase of the module manufacturing method after performing step b) 148 , step c) 150 , step e) 154 and step f) 156 can be illustrated exemplarily. Figure 4c The third and final stage of the module manufacturing method after performing step d) 152 may be illustrated exemplarily.

[0087] Reference numerals list

[0088] 110 Thermal Management Module

[0089] 112 Fluid Channels

[0090] 114 Entrance

[0091] Exit 116

[0092] 118 Fluid Pump

[0093] 120 Heating Elements

[0094] 122 Cooling fluid

[0095] 124Plastic parts

[0096] 126 side arm

[0097] 128 Feeding pipeline

[0098] 130 Mixing Valve

[0099] 132 Temperature Sensor

[0100] 134 load-bearing components

[0101] 136 Cover parts

[0102] 138 Fluid pump protrusion

[0103] 140 Heating element recess

[0104] 142 sensor recess

[0105] 144 valve recess

[0106] 146 Step a)

[0107] 148 Step b)

[0108] 150 Step c)

[0109] 152 Step d)

[0110] 154 Step e)

[0111] 156 Step f)

Claims

1. A thermal management module (110), the thermal management module (110) being used to control the temperature of a battery pack in a vehicle, the thermal management module (110) comprising: - at least one fluid channel (112) for directing a cooling fluid (122) through the thermal management module (110), wherein the fluid channel (112) comprises two or three plastic parts (124), wherein the fluid channel (112) comprises at least one inlet (114) and at least one outlet (116); - at least one fluid pump (118) for driving the cooling fluid (122) to move through the fluid channel (112), wherein the fluid pump (118) is fixed to the fluid channel (112); - at least one heating element (120), the heating element (120) being arranged at least partially within the fluid channel (112) such that the cooling fluid (122) can be heated by the heating element (120).

2. The thermal management module (110) according to the preceding claim, wherein: The fluid channel (112) completely surrounds the heating element (120) in at least one plane.

3. The thermal management module (110) according to any one of the preceding claims, wherein: The heating element (120) is arranged inside the fluid channel (112) such that the heating element (120) is arranged within a flow path of the cooling fluid (122) in the fluid channel (112).

4. The thermal management module (110) according to any one of claims 1 and 2, wherein: The heating element (120) protrudes into the fluid channel (112) such that the heating element (120) penetrates a wall of the fluid channel (112).

5. The thermal management module (110) according to any one of the preceding claims, wherein: The heating element (120) includes at least one resistive heating wire.

6. The thermal management module (110) according to any of the preceding claims, further comprising at least one temperature sensor (132) for measuring the temperature of the cooling fluid (122), wherein The temperature sensor (132) is arranged in the fluid channel (112).

7. The thermal management module (110) of any one of the preceding claims, further comprising at least one mixing valve (130) for mixing cooling fluid (122) from different parts of the fluid channel (112), wherein: The mixing valve (130) is arranged in a flow path of the fluid passage (112) and is fixed to the fluid passage (112).

8. The thermal management module (110) according to the preceding claim, wherein The mixing valve (130) is one or more of a two-way mixing valve and a three-way mixing valve.

9. The thermal management module (110) according to any one of the preceding claims, wherein: The material of the first plastic component among the plastic components (124) is consistent with the material of the second plastic component among the plastic components (124).

10. The thermal management module (110) according to any one of the preceding claims, wherein: At least one of the plastic parts (124) of the fluid channel (112) comprises a plastic material selected from the group consisting of: a thermoplastic material, such as polypropylene (PP) and / or polyamide (PA); a thermosetting material.

11. A module manufacturing method for manufacturing a thermal management module (110), the method comprising: a) producing two or three plastic parts (124) for the fluid channel (112) during an injection molding process; b) providing at least one fluid pump (118) and arranging the fluid pump (118) on one of the plastic components (124); c) providing at least one heating element (120) and arranging the heating element (120) on one of the plastic parts (124); d) joining the two or three plastic parts (124) in one or more welding processes, thereby creating the fluid channel (112).

12. Module manufacturing method according to the preceding claim, wherein: Before performing step d), the method further comprises: e) providing at least one temperature sensor (132) and arranging the temperature sensor (132) on one of the plastic components (124).

13. A module manufacturing method according to any one of the preceding claims relating to a module manufacturing method, wherein: Before performing step d), the method further comprises: f) providing at least one mixing valve (130) and arranging the mixing valve (30) on one of the plastic components (124).

14. A module manufacturing method according to any one of the preceding claims relating to a module manufacturing method, wherein: The module manufacturing method is configured for manufacturing a thermal management module (110) according to any one of the preceding claims relating to a thermal management module (110).

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