A thermal management integrated module structure and vehicle suitable for R290 refrigerant

Abstract

This invention discloses a thermal management integrated module structure and vehicle applicable to R290 refrigerant, which includes a coolant substrate and a refrigerant substrate. The coolant substrate is provided with a coolant assembly, and the refrigerant substrate is provided with a refrigerant assembly. The refrigerant assembly includes a compressor, which is located at one end of the refrigerant substrate. The thermal management integrated module structure applicable to R290 refrigerant of this invention has the advantages of fewer connecting pipes, light weight, and compact layout, and can reduce the flammability risk of R290 refrigerant.

Description

Technical Field

[0001] This invention belongs to the field of automotive thermal management technology. Specifically, this invention relates to a thermal management integrated module structure applicable to R290 refrigerant. Background Technology

[0002] With increasingly stringent environmental protection requirements, the commonly used R134a refrigerant can no longer meet the relevant requirements. Therefore, a new environmentally friendly refrigerant is urgently needed to replace it. R290 refrigerant was developed to address this need. R290 has excellent thermal properties, is inexpensive, and has a large cooling capacity per unit volume, making it a relatively ideal refrigerant. However, it has the disadvantage of being flammable. Current vehicle thermal management systems are designed by disassembling and fixing various components in different parts of the vehicle. This results in a large number of parts, requires a large amount of space, has complex piping connections, and poses significant challenges to the overall vehicle layout. Due to the complex piping layout, leaks during the refilling of R290 refrigerant can create a flammable risk.

[0003] Utility model patent CN221914005U, published on October 29, 2024, discloses a thermal management module and a vehicle. The thermal management module includes a water pump, a water valve, and an integrated water tank. The integrated water tank includes a flow channel plate and an expansion tank. The flow channel plate includes a first substrate and a second substrate, which are oppositely disposed and fixedly connected. At least one flow channel is formed between the first substrate and the second substrate. The expansion tank, water pump, and water valve are all fixedly connected to the flow channel plate and communicate with at least one flow channel. The water valve controls the flow pattern of the at least one flow channel. However, this thermal management module does not solve the aforementioned technical problem. Summary of the Invention

[0004] The purpose of this invention is to address the shortcomings of existing technologies by providing a lightweight, compact, and less interconnected thermal management integrated module structure suitable for R290 refrigerant, which reduces the risk of refrigerant flammability.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0006] The thermal management integrated module structure applicable to R290 refrigerant includes a coolant substrate and a refrigerant substrate. The coolant substrate is provided with a coolant assembly, and the refrigerant substrate is provided with a refrigerant assembly. The refrigerant assembly includes a compressor, which is located at one end of the refrigerant substrate.

[0007] The other end of the refrigerant substrate is provided with a water-cooled condenser, a liquid storage tank and a cooler; the compressor and the refrigerant substrate are connected by a first pipeline, and the compressor and the water-cooled condenser are connected by a second pipeline.

[0008] The coolant assembly includes a multi-way valve, a three-way valve, and a water pump, with the water pump located between the multi-way valve and the three-way valve.

[0009] The refrigerant substrate has a first support at the bottom of both sides, and steps at both ends of the top of the refrigerant substrate. A second support is provided on the steps. Both the first and second supports are provided with shock-absorbing blocks, and the shock-absorbing blocks have fixing holes in the middle.

[0010] The multi-way water valve is located in the middle of the coolant substrate, and the three-way water valve is located at both ends of the coolant substrate.

[0011] The coolant substrate and the refrigerant substrate are arranged in parallel.

[0012] The refrigerant assembly is disposed on the outside of the refrigerant substrate, and the coolant assembly is disposed on the outside of the coolant substrate.

[0013] The first and second supports have openings at their ends, and the shock absorber blocks are engaged in the openings.

[0014] The water pumps are installed in pairs.

[0015] The vehicle includes the aforementioned thermal management integrated module structure for R290 refrigerant.

[0016] The technical advantages of this invention are as follows: By adopting the R290 refrigerant-compatible thermal management integrated module structure of this invention, and integrating the thermal management components, compared with traditional thermal management components, an integrated refrigerant substrate and coolant substrate are used, reducing the number of connecting pipes between components, effectively reducing the number of brackets and connecting pipes, and lowering the overall vehicle weight. This offers advantages such as lightweight, low cost, and integration, resulting in a more compact overall layout, saving vehicle space, improving vehicle space utilization, and increasing driving range due to weight reduction. The compressor is synchronously integrated into the thermal management integrated module, forming an independent, integrated closed-loop refrigerant circuit, effectively reducing the risk of flammability caused by R290 refrigerant leakage and ensuring vehicle safety. The thermal management integrated module and the vehicle are connected in an integrated soft connection, ensuring reliable NVH performance. Attached Figure Description

[0017] This manual includes the following figures, which illustrate the following:

[0018] Figure 1 This is a schematic diagram of the structure of the thermal management integrated module applicable to R290 refrigerant of the present invention;

[0019] Figure 2 This is another perspective structural diagram of the thermal management integrated module structure applicable to R290 refrigerant of the present invention.

[0020] The following are marked in the diagram: 1. Coolant base plate; 2. Refrigerant base plate; 3. Compressor; 4. Receiver tank; 5. Water-cooled condenser; 6. Cooler; 7. Multi-way water valve; 8. Water pump; 9. Three-way water valve; 10. Shock absorber; 11. First bracket; 12. Second bracket; 13. First pipeline; 14. Second pipeline; 15. Step; 16. Fixing hole; 17. Opening. Detailed Implementation

[0021] The specific embodiments of the present invention will be further described in detail below with reference to the accompanying drawings, in order to help those skilled in the art to have a more complete, accurate and in-depth understanding of the inventive concept and technical solution of the present invention, and to facilitate its implementation.

[0022] like Figure 1 and Figure 2 As shown, the thermal management integrated module structure applicable to R290 refrigerant has a coolant assembly on a coolant substrate 1 and a refrigerant assembly on a refrigerant substrate 2; the refrigerant assembly includes a compressor 3, which is located at one end of the refrigerant substrate 2.

[0023] As the core component of the thermal management system, the compressor 3 is integrated on the refrigerant base plate 2, which can improve the operating efficiency of the thermal management system, enable the thermal management system to have a faster response and lower energy consumption, ensure operational reliability, reduce the number of pipelines and components, reduce the size, and save overall vehicle layout space.

[0024] This integrated thermal management module connects the compressor 3, receiver 4, three-way water valve 9, water pump 8, multi-way water valve 7, water-cooled condenser 5, and chiller 6 via a coolant base plate 1 and a refrigerant base plate 2. The coolant base plate 1 and refrigerant base plate 2 are mutually fixed, and their internal flow channels are effectively insulated through topological and perforated structures to prevent heat transfer and mixing between circuits at different temperatures, which could lead to thermal management performance failure. The refrigerant circuit connects the refrigerant-side components through the first pipe 13, the second pipe 14, and the internal flow channels of the refrigerant base plate 2, forming a complete closed-loop circuit. This reduces the length and complexity of the refrigerant circuit, effectively preventing R290 refrigerant leakage and secondary refilling, and lowering the risk of flammability. The overall vehicle thermal management solution achieves the required thermal management for the entire vehicle through heat exchange between the coolant and refrigerant within the integrated module.

[0025] like Figure 1As shown, the other end of the refrigerant substrate 2 is equipped with a water-cooled condenser 5, a liquid receiver 4, and a cooler 6; the compressor 3 is connected to the refrigerant substrate 2 by a first pipeline 13, and the compressor 3 is connected to the water-cooled condenser 5 by a second pipeline 14. The refrigerant substrate 2 integrates the above components into one unit, replacing the traditional interconnecting pipelines with internal flow channels, reducing the number of supports and pipelines, and lowering the assembly workload. Through the integrated arrangement of the above components, the failure rate of component electrical control can be significantly reduced, facilitating periodic maintenance. The water-cooled condenser 5, liquid receiver 4, and cooler 6 are concentrated at one end of the refrigerant substrate 2, making full use of the side space of the refrigerant substrate 2, which is conducive to reducing the design length and width of the refrigerant substrate 2, thereby reducing the overall volume. The refrigerant sequentially passes through the compressor 3, water-cooled condenser 5, liquid receiver 4, and cooler 6, and then returns to the compressor 3 to form a refrigerant circuit. In the above cycle, the heat exchange process with the coolant is completed. Except for the flow paths of the first pipeline 13 and the second pipeline 14, the refrigerant connects to the above components through the internal flow channels of the refrigerant substrate 2.

[0026] like Figure 2 As shown, the coolant assembly includes a multi-way water valve 7, a three-way water valve 9, and a water pump 8, with the water pump 8 located between the multi-way water valve 7 and the three-way water valve 9. The coolant base plate 1 has internal flow channels that communicate with the multi-way water valve 7, the three-way water valve 9, and the water pump 8, enabling the inflow and outflow, on / off switching, and heat exchange of the coolant. The multi-way water valve 7 and the three-way water valve 9 are used to connect multiple thermal management components in the vehicle's thermal management system, thereby controlling the on / off switching of different thermal management circuits. The water pump 8 provides power for the coolant flow and is positioned between the two types of water valves to facilitate the staggered arrangement of their connectors.

[0027] like Figure 1 and Figure 2 As shown, the refrigerant substrate 2 has first supports 11 at both bottom ends and steps 15 at both top ends. Second supports 12 are mounted on the steps 15. Both the first supports 11 and the second supports 12 have damping blocks 10, with a fixing hole 16 in the center of each damping block 10. This thermal management integrated module is connected to the vehicle via the damping blocks 10, achieving NVH (Noise, Vibration, and Harshness) performance. The four damping blocks 10 absorb vibrations caused by road surface excitation, avoiding the impact of traditional rigid connections on the stability of the thermal management integrated module. The stepped structure at both top ends of the refrigerant substrate 2 reduces the space occupied by the second supports 12 at the top of the refrigerant substrate 2. The fixing holes 16 connect the damping blocks 10 to the vehicle body via connectors, forming a flexible connection with the vehicle body. The axis of the damping blocks 10 on the first support 11 is parallel to the side of the refrigerant substrate 2, while the axis of the damping blocks 10 on the second support 12 is perpendicular to the refrigerant substrate 2. This two-way connection of the damping blocks 10 at the top and bottom of the refrigerant substrate 2 improves the overall structural stability. The second support 12 is a planar structure with raised ribs on both sides to enhance its connection strength.

[0028] like Figure 2 As shown, the multi-way water valve 7 is located in the middle of the coolant base plate 1, and the three-way water valves 9 are located at both ends of the coolant base plate 1. Installing the multi-way water valve 7 in the middle of the coolant base plate 1 facilitates the arrangement of connecting pipes and reduces spatial interference with surrounding components. Installing the three-way water valves 9 at both ends of the coolant base plate 1 further reduces the space occupied by the valve body and allows for staggered arrangement of the pipes connected to the multi-way water valve 7, reducing space occupation and making the pipe distribution more rational. The outlet ends of the two three-way water valves 9 are embedded in the coolant base plate 1 and face opposite sides of the coolant base plate 1, achieving both the effect of reducing the number of fixed supports and avoiding spatial interference between the pipes of the two three-way water valves 9.

[0029] like Figure 1 and Figure 2 As shown, the coolant substrate 1 and the refrigerant substrate 2 are arranged in parallel. In this structure, the refrigerant assembly and coolant assembly are separated by the two substrates, reducing the impact of heat radiation from the refrigerant circuit and the coolant circuit. The parallel arrangement of the two substrates facilitates the vertical and stable installation of the module within the vehicle body. Furthermore, both substrates are plate-shaped structures of uniform thickness, facilitating their relative arrangement, reducing manufacturing costs, and providing stable mounting positions for components on the substrates.

[0030] like Figure 1 and Figure 2 As shown, the refrigerant assembly is located on the outside of the refrigerant base plate 2, and the coolant assembly is located on the outside of the coolant base plate 1. The coolant assembly and refrigerant assembly are respectively arranged on the sides of the two base plates, which does not occupy the space of the outer edge of the base plates and does not significantly increase the overall volume of the module. This helps to provide space for other components in the vehicle body. At the same time, the connection ends of the pipes connected to each component are in opposite directions, reducing spatial interference and simplifying the assembly operation when laying out the pipes.

[0031] like Figure 1 and Figure 2 As shown, the first bracket 11 and the second bracket 12 have openings 17 at their ends, and the shock absorber 10 is snapped into the openings 17. The shock absorber 10 is installed with the bracket by snapping and is fastened to the vehicle body with a connector to form a flexible connection. The shock absorber 10 is not easy to fall out, and the installation and removal process of the shock absorber 10 is convenient for later replacement, thus improving efficiency.

[0032] like Figure 2 As shown, the water pumps 8 are arranged in pairs. The multiple water pumps 8 increase the flow rate of the coolant, improve the response speed of thermal management, and facilitate the circulation and heat dissipation process of the coolant. This helps regulate the operating temperature of components such as the car engine, battery, and air conditioning, preventing overheating and maintaining a suitable operating temperature range.

[0033] The vehicle includes the aforementioned thermal management integrated module structure using R290 refrigerant. In this integrated solution, where all thermal management components are interconnected and fixed, the heat exchange of the refrigerant in the internal thermal management system primarily occurs on the thermal management integrated module. The refrigerant and coolant sides are connected via substrates, forming an independent closed loop using R290 refrigerant. This eliminates the need for refilling, removing safety hazards caused by leaks during refilling due to the refrigerant's flammability. Compared to existing vehicles, this solution offers advantages such as fewer thermal management components and connecting pipes, lower cost, and simpler layout space.

[0034] This R290 refrigerant-compatible thermal management integrated module structure, by integrating thermal management components, adopts an integrated refrigerant base plate 2 and coolant base plate 1 compared to traditional thermal management components. This reduces the number of connecting pipes between components, effectively reducing the number of brackets and connecting pipes, and lowering the overall vehicle weight. It has the advantages of lightweight, low cost, and integration, making the overall layout more compact, saving vehicle space, improving vehicle space utilization, and the weight reduction also increases the driving range. The compressor 3 is synchronously integrated into the thermal management integrated module, forming an independent integrated closed-loop circuit for the refrigerant circuit, effectively reducing the risk of flammability caused by R290 refrigerant leakage and ensuring vehicle safety. The thermal management integrated module and the vehicle adopt an integrated soft connection, ensuring reliable NVH performance.

[0035] The present invention has been described above by way of example with reference to the accompanying drawings. Obviously, the specific implementation of the present invention is not limited to the above-described manner. Any non-substantial improvements made using the inventive concept and technical solution; or the direct application of the inventive concept and technical solution to other situations without modification, are all within the protection scope of the present invention.

Claims

1. A thermal management integrated module structure applicable to R290 refrigerant, characterized in that: The system includes a coolant substrate (1) and a refrigerant substrate (2). The coolant substrate (1) is provided with a coolant assembly, and the refrigerant substrate (2) is provided with a refrigerant assembly. The refrigerant assembly includes a compressor (3), which is located at one end of the refrigerant substrate (2). The coolant assembly includes a multi-way water valve (7), a three-way water valve (9), and a water pump (8), which is located between the multi-way water valve (7) and the three-way water valve (9). The bottom ends of both sides of the refrigerant substrate (2) are provided with first supports (11), and the top ends of the refrigerant substrate (2) are provided with steps (15), and the steps (15) are provided with a first support (11). Two supports (12), the first support (11) and the second support (12) are provided with shock-absorbing blocks (10), and the shock-absorbing blocks (10) are provided with fixing holes (16) in the middle; the multi-way water valve (7) is located in the middle of the coolant substrate (1), and the three-way water valve (9) is located at both ends of the coolant substrate (1); the axis of the shock-absorbing block (10) on the first support (11) is parallel to the side of the refrigerant substrate (2), and the axis of the shock-absorbing block (10) on the second support (12) is perpendicular to the refrigerant substrate (2); the outlet ends of the two three-way water valves (9) are embedded on the coolant substrate (1) and face the two sides of the coolant substrate (1) respectively.

2. The thermal management integrated module structure applicable to R290 refrigerant according to claim 1, characterized in that: The other end of the refrigerant substrate (2) is provided with a water-cooled condenser (5), a liquid storage tank (4) and a cooler (6); the compressor (3) and the refrigerant substrate (2) are connected by a first pipeline (13), and the compressor (3) and the water-cooled condenser (5) are connected by a second pipeline (14).

3. The thermal management integrated module structure applicable to R290 refrigerant according to claim 1, characterized in that: The coolant substrate (1) and the refrigerant substrate (2) are arranged in parallel.

4. The thermal management integrated module structure applicable to R290 refrigerant according to claim 3, characterized in that: The refrigerant assembly is located on the outside of the refrigerant substrate (2), and the coolant assembly is located on the outside of the coolant substrate (1).

5. The thermal management integrated module structure applicable to R290 refrigerant according to claim 1, characterized in that: The first bracket (11) and the second bracket (12) have openings (17) at their ends, and the shock absorber (10) is snapped into the opening (17).

6. The thermal management integrated module structure applicable to R290 refrigerant according to claim 1, characterized in that: The water pumps (8) are installed in pairs.

7. A vehicle, characterized in that: The thermal management integrated module structure for R290 refrigerant as described in any one of claims 1-6 is included.

Images