Thermal management module and vehicle having at least one such thermal management module

Abstract

The invention relates to a thermal management module (1) for managing a mass flow rate of a temperature control medium of at least one temperature control circuit in a vehicle, wherein the thermal management module (1) comprises at least one module housing (10), at least one fluid connection device (50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64) and at least one fluid path inside the module housing (10). According to the invention, the module housing (10) comprises at least one carrier component (2) and at least one cover element (3), the at least one carrier component (2) and the at least one cover element (3) being connectable or connected to each other and forming between them at least one fluid channel (4, 4a, 4b, 4c, 4d, 4e) as a fluid path.

Description

Technical Field

[0001] The present invention relates to a thermal management module for managing the mass flow of a temperature control medium in at least one temperature control loop in a vehicle, the thermal management module comprising at least one module housing, at least one fluid connection device and at least one fluid path inside the module housing, and a vehicle having at least one temperature control loop for temperature control of vehicle components, in particular at least one battery and at least one electronic component, wherein at least one thermal management module is used to manage the mass flow of a temperature control medium in at least one temperature control loop. Background Art

[0002] In today's vehicles, especially electric and hybrid vehicles, more and more electronic control components, such as electrically adjustable control valves, electrically adjustable pumps, a large number of sensors, etc., are arranged along the fluid circuit or temperature control circuit (such as cooling circuit) of the vehicle. Therefore, the advantage of this thermal management optimized on demand and driving state is that it supports driving comfort on the one hand and supports the optimization of vehicle range on the other hand. The temperature control medium used is guided in a closed system of the temperature control circuit of the vehicle. Such a temperature control circuit includes at least one first sub-circuit for temperature control of the power battery, at least one second sub-circuit for temperature control of at least one electronic component, and at least one third sub-circuit containing a heat exchanger, which is used to absorb heat from the ambient air of the vehicle and release heat to it, and is also passed through by the temperature control medium, so that heat can be transferred to the temperature control medium and from it to the ambient air through the heat exchanger. Through the third sub-circuit, the air conditioning comfort of the vehicle interior or the cockpit can also be adjusted. Each sub-circuit has a supply flow and a return flow. In order to manage the mass flow of a temperature control medium of such a temperature control circuit in a vehicle, a thermal management module may be provided, which comprises a module housing, some fluid connections and fluid channels inside the module housing.

[0003] For example, from DE102020206268A1, a thermal management system for a motor vehicle battery, in particular an electric vehicle, a battery electric vehicle or a hybrid electric vehicle, is known, the system comprising a control unit, a first coolant circuit and a second coolant circuit, wherein the first coolant circuit has a battery, a cooler and a first pump, and the second coolant circuit has a heater, a heating heat exchanger and a second pump. The first and second cooling circuits are coupled to each other in heat or thermal fluid via a coupling device. The control unit is designed to adjust the performance of the first pump and the second pump to meet the requirements of thermal management. From the literature of this prior art, it can be seen that the complexity of this thermal management system with multiple cooling circuits, which includes multiple components such as pumps, batteries, heaters, etc., and the cooling circuits are coupled to each other and nested with each other.

[0004] To solve this problem, DE102021102473A1 proposes a thermal management module for a motor vehicle cooling system with an electric drive system, the module having a module housing with a plurality of coolant interfaces, wherein the coolant interfaces include a first coolant interface, a second coolant interface and a third coolant interface, and a control valve for controlling the flow of fluid between the coolant interfaces is arranged in the module housing. The thermal management module has a first connecting pipe for transmitting coolant, wherein the first connecting pipe couples the first coolant interface with the second coolant interface in a fluid-through manner. An internal space is formed inside the module housing of the thermal management module, in which a control valve designed as a rotary slide valve is arranged. Through the control valve, the fluid-through coupling between the various coolant interfaces can be switched and interrupted. For this purpose, the control valve has a valve chamber with valve chamber openings, which can be aligned with the corresponding coolant interfaces, so that at least two coolant interfaces can be fluid-through connected together through the valve chamber. Therefore, this thermal management module is a special valve for special applications in the form of a 9 / x channel valve for regulating the flow of cooling medium in different branches of the cooling system, and the design is very complex and expensive. It has a module housing, into which the other components mentioned above are inserted and attached. The complex structure of the thermal management module in the form of a multi-way valve has proven to be disadvantageous. In addition, it is relatively prone to errors and cannot be multifunctional or universally used. Summary of the invention

[0005] The object of the present invention is therefore to develop a thermal management module for managing the mass flow of a temperature control medium of at least one temperature control circuit in a vehicle, wherein the thermal management module comprises at least one module housing, at least one fluid connection device and at least one fluid path inside the module housing, and a vehicle having at least one such thermal management module so that any number of fluid paths, as well as partially differently designed and flow-optimized fluid paths, can be easily formed in the module housing.

[0006] This object is achieved by a thermal management module according to the preamble of claim 1, wherein the module housing comprises at least one load-bearing structural component and at least one cover element, which can be connected to one another or are connected to one another and form at least one fluid channel as a fluid path therebetween. This object is also achieved by a vehicle having at least one temperature control circuit for temperature control of vehicle components, in particular at least one battery and at least one electronic component, wherein at least one such thermal management module is provided for managing the mass flow of a temperature control medium in at least one temperature control circuit. Further developments of the invention are given in the dependent claims.

[0007] Therefore, a thermal management module is proposed for managing the mass flow of a temperature control medium of at least one temperature control circuit in a vehicle, wherein the module housing comprises at least one load-bearing structural component and at least one cover element. The at least one load-bearing structural component and the at least one cover element can be connected or are connected to each other, in particular, they are connected in a materially bonded manner, for example, by welding. Between the two components of the module housing, i.e., between the at least one load-bearing structural component and the at least one cover element, at least one fluid channel is formed as a fluid path inside the module housing. Therefore, both the at least one load-bearing structural component and the at least one cover element are preferably designed as a shell-like hollow shape. After the at least one load-bearing structural component and the at least one cover element are combined, at least one channel-shaped cavity, i.e., at least one fluid channel, remains between them. The at least one fluid channel can be flowed through by a temperature control medium. It is used for fluid connection of at least one temperature control medium conveying component and at least one temperature control medium mass flow regulating component, which components are arranged on and / or inside the load-bearing structural component, or in the module housing and in the fluid channel formed inside, and are connected to these components via a fluid connection device provided on the thermal management module, to which a shut-off pipe can be connected.

[0008] In order to provide an application-specific optimal shaping of at least one load-bearing structural component and / or at least one cover element and correspondingly an optimal shaping of at least one fluid channel formed therebetween, at least one load-bearing structural component and / or at least one cover element can be designed, for example, as an injection-molded part, a deep-drawn part or a die-cast part, in particular a plastic injection-molded part. In particular, when providing a plastic injection-molded part, at least one load-bearing structural component and at least one cover element can advantageously be materially connected together or already connected together by laser welding. Of course, other types of materially connected connections can also be provided to achieve a media-tight connection of at least one load-bearing structural component and at least one cover element.

[0009] At least one load-bearing structural component is preferably designed to be able to arrange or have arranged or integrated at least one component for conveying a temperature control medium and at least one component for mass flow regulation, in particular at least two components for conveying a temperature control medium and at least one component for mass flow regulation. Managing the mass flow means that the mass flow of the fluid medium is conveyed, in particular pumped, through at least one component for conveying a temperature control medium in the thermal management module, and is metered, adjusted or controlled accordingly through at least one component for mass flow regulation and conveyed to the various fluid connections of the thermal management module so that they can flow in the various pipes of the temperature control circuit or its sub-circuits, in which the vehicle components that need temperature control are arranged to achieve the corresponding temperature control. The vehicle components that need temperature control are, for example, batteries, such as power batteries, and electronic components, and heat exchangers and / or temperature control devices or heat sources and / or heat sinks can be arranged in the sub-circuits.

[0010] At least one load-bearing structural component is preferably designed to be able to arrange or has arranged at least one component for conveying a temperature control medium and at least one component for mass flow control, in particular at least two components for conveying a temperature control medium and at least one component for mass flow control. In order to arrange at least one component for conveying a temperature control medium and at least one component for mass flow control, the shell-shaped load-bearing structural component is, for example, equipped with one or more receiving sections, on which these components can be optimally received. In particular, at least one load-bearing structural component can have at least one through-hole, through which a drive shaft or other component parts can enter at least one fluid channel inside the module housing formed by material-fitting connection of at least one load-bearing structural component and at least one cover element. The component can penetrate the wall of the load-bearing structural component in order to enter at least one fluid channel and intervene, so that the mass flow of the temperature control medium flowing therethrough can be regulated. It is further advantageous that at least one load-bearing structural component or the thermal management module can be designed or manufactured so that at least one component for conveying a temperature control medium, such as a pump device, and at least one component for mass flow control, such as a valve, can be installed or can be installed from the same side of at least one load-bearing structural component or the thermal management module. The supporting structural component can thus be assembled from one side, which greatly simplifies the installation of the component on the supporting structural component due to the easy accessibility of the receiving section of the supporting structural component.

[0011] At least one cover element can be designed as a single part or as a multi-part element. Thus, a plurality of fluid channels separated from one another can be generated within the module housing. This can be achieved in particular by providing a plurality of cover elements separated from one another, which are connected to the load-bearing structural component at respective predetermined, separated positions, so that fluid channels are formed between the load-bearing structural component and the cover element.

[0012] Furthermore, a single cover element can be provided and shaped so that it has shaped or designed sections for forming a fluid channel between the load-bearing structural component and the cover element, and flat or at least not for forming a fluid channel connecting sections, which are located between the shaped sections of the cover element and connect these sections to form an integral cover element. By providing a single cover element, the rigidity of the module housing can be increased compared to providing a plurality of cover elements that are separated from each other and connected to the load-bearing structural component.

[0013] Thus, a single-part, segmented or multi-part cover element can be provided and connected or connected to the load-bearing structural component. In order to withstand high pressure loads, it is suitable to design the cover element to be small in area, which can be achieved by providing a multi-part cover element or a cover element with profiled sections and connecting sections arranged between them.

[0014] The connection region in which at least one cover element and at least one load-bearing structural component are connected to each other by material fit, in particular by welding, such as laser welding, is preferably located in the same plane. The cover element and the load-bearing structural component themselves have rigidity, in particular the cover element has a large surface rigidity. In this way, the weld between the cover element and the load-bearing structural component can be supported, so that due to the surface rigidity of at least one cover element, in particular the surface rigidity of a single-part cover element, the load on at least one weld between the (multiple) cover elements and the load-bearing structural component can be relieved, in particular when the complete weld lies in the same plane. When the module housing is subjected to internal pressure in the region of its load-bearing structural component and / or its cover element (its multiple cover elements), the welded connection may be subject to tensile stress. On a flat cover element, shear stresses may occur due to the bulge of the cover element. The internal pressure is generated when the temperature control medium flowing in at least one fluid channel formed between the load-bearing structural component and the (multiple) cover elements is under pressure. In the one-part design of the cover element, the entire welding zone or weld seam, as described above, lies in one plane, which simplifies the manufacturing process of the thermal management module, since only one component in the form of the cover element is welded to the load-bearing structural component in one plane, without increasing the filling volume or causing disadvantages due to an unfavorable flow of the temperature control medium in the at least one fluid channel inside the module housing. Increasing the filling volume would lead to a weight disadvantage of the thermal management system or its fluid channels in the filled state.

[0015] In particular, at least one cover element, but at least one load-bearing structural component can also be further preferably designed as a two-component component. For example, a region of at least one cover element and at least one load-bearing structural component (which region forms or includes a weld between the two) can be designed to be more stable, while another region is more elastic or flexible. If the weld between the cover element(s) and the load-bearing structural component is made of a stable material, a particularly stable welded connection or weld between the cover element and the load-bearing structural component can advantageously be produced. Deformations of the components can advantageously be allowed by providing structurally more elastic regions, such as grid-like regions, in order to avoid damage to the thermal management module or its load-bearing structural components and the cover element in extreme load situations, such as impact loads. Likewise, deformations of the components can be allowed by using more elastic or flexible materials in functionally critical areas or areas away from the weld.

[0016] In a multi-part design of the cover element, the cover part can be connected to at least one load-bearing structural component in multiple planes. Thus, in a multi-part cover element, the load-bearing structural component and the multi-part cover element or the cover elements can be welded in multiple planes. However, this proves to be laborious and is therefore less popular. In principle, even in the case of a multi-part design of the cover element or the multi-part component, it is also possible to weld it to the load-bearing structural component in one plane.

[0017] The load-bearing structural component of the thermal management module is preferably designed to be essentially flat, which means that its height extension is significantly smaller than its planar extension. In the region where the fluid connection device is formed or designed in the direction of its height extension, the height of the load-bearing structural component is significantly greater than the height of the predetermined region between the load-bearing structural components. By providing a height extension that is significantly smaller than the planar extension, on the one hand, a space-saving design of the load-bearing structural component in the direction of its height extension and, on the other hand, a stable design can be achieved.

[0018] At least one cover element can further advantageously be designed to be at least partially groove-shaped in order to form different flow cross sections of at least one fluid channel between the at least one cover element and the at least one load-bearing structural component. This groove shape of the cover element forms a first half shell or partial shell of the fluid channel cross section, while the hollow shape or shell shape of the load-bearing structural component forms a second half shell or partial shell of the fluid channel cross section, so that after the partial shells or half shells of the cover element and the load-bearing structural component are connected, a complete fluid channel cross section is formed.

[0019] It is further advantageous that, in order to optimize the flow of the temperature control medium flowing in at least one fluid channel inside the module housing of the thermal management module, at least one cover element is shaped differently in multiple dimensions in its cross section. For example, at least one cover element can have a protruding or cantilevered section and a recessed or groove-shaped section in the direction toward the load-bearing structural component. Therefore, the flow cross section of the fluid channel formed between the load-bearing structural component and the cover element can be smaller in the area of ​​the protruding or cantilevered section than in the area of ​​the recessed or groove-shaped section of the cover element. By means of the multi-dimensional different shaping of at least one cover element, such a shape can be given to the cover element within its extension range so that fluid channels of different shapes and / or sizes in sections are generated between the cover element and at least one load-bearing structural component, and have correspondingly different flow cross sections. Therefore, different components that can be arranged on and / or inside the load-bearing structural component, i.e., at least one component for conveying the temperature control medium, such as at least one pump device, and at least one component for mass flow regulation, such as at least one valve, can also have very different mass flows flowing through the fluid channel inside the module housing in different areas of the thermal management module according to the requirements of the respective application scenarios.

[0020] Furthermore, one or more sensors can be arranged in the at least one cover element, in particular in the region of the at least one fluid channel or in the at least one fluid channel. For example, one or more sensors can be integrated into the at least one cover element, for example at least one temperature sensor, and can protrude into flow contours forming the fluid channel, which together with the shaping in the load-bearing structural component form the fluid channel, or collect data there.

[0021] The fluid channel generated inside the module housing of the thermal management module is in fluid connection with a fluid connection device which is also arranged or formed on the module housing. A medium pipeline in the form of a hose and / or a pipe can be connected to the fluid connection device. The temperature control circuit of the vehicle can include a plurality of sub-circuits, in particular at least three sub-circuits, whose respective media pipelines are respectively connected to the fluid connection device of the thermal management module or can be connected to the fluid connection device of the thermal management module. Various components of the vehicle can be supplied with a temperature control medium (e.g. a coolant) through the sub-circuits of the temperature control circuit. In order to allow a flow suitable for each component or sub-circuit to flow through the module housing of the thermal management module, the possibility of arranging fluid channels of different shapes and / or sizes inside the module housing of the thermal management module has proven to be very advantageous. In order to optimize the flow, different flow cross-sections can advantageously be provided through which different volumes of temperature control medium can flow.

[0022] It is further advantageous that at least one fluid connection device can be arranged or formed on at least one load-bearing structural component and / or at least one cover element. It is particularly preferred that at least one fluid connection device is formed on the load-bearing structural component. In particular, at least one fluid connection device can extend along the bending direction of the hollow shape or shell shape of the load-bearing structural component, that is, along the height direction of the load-bearing structural component, and / or along its plane extension direction, that is, approximately perpendicular to its height direction. The formation of the fluid connection device along the bending direction of the hollow or shell shape of the load-bearing structural component is conducive to good demoulding of the load-bearing structural component, and when it is manufactured by an injection molding process, it can be easily demoulded after opening the injection mold. However, demoulding of the fluid connection device arranged along the plane extension direction of the load-bearing structural component is also easy and feasible.

[0023] In particular, when a large number of fluid connections are provided, these devices are closely adjacent or in a small space on or near the load-bearing structural component, which may cause problems when demoulding them, because the bottom slide of the injection mold will collide with the adjacent fluid connection device when opening to demould the injection-molded load-bearing structural component. This will lead to the inability to demould, or at least the inability to demould without damaging the fluid connection device. This problem can be solved in the following way: at least one fluid connection device is composed of at least one receiving section formed in at least one load-bearing structural component and at least one fluid connection section formed in at least one cover element and can be inserted or has been inserted into at least one receiving section. In this way, the fluid connection section formed in at least one cover element is inserted into the receiving section in the load-bearing structural component and forms a fluid connection device together with it. Although the arrangement of the fluid connection section in the cover element makes the tool design of the cover element more complicated, more installation space can be obtained thereby, so that a plurality of fluid connections can be arranged in a smaller space.

[0024] It is further advantageous that at least one sealing element can be used for fluid-tight connection of receiving section and fluid connecting section and can be arranged or is arranged between them. Since the fluid connecting section is inserted into the receiving section of the load-bearing structural component on the cover element, it has proven to be particularly advantageous to seal the connection by providing at least one sealing element.

[0025] At least one load-bearing structural component can be at least partially formed in a grid shape. In particular, in the grid-shaped area of ​​at least one load-bearing structural component, it is advantageous not to provide a cover element, or at least one cover element extends only outside at least one grid-shaped area of ​​the load-bearing structural component. Only at least one grid-shaped area formed in the load-bearing structural component can realize the thermal decoupling of a single area of ​​the load-bearing structural component from other adjacent areas, because there is little or almost no heat transferred through the individual grid-shaped segments of the load-bearing structural component. Other areas of the load-bearing structural component can be thermally coupled in a targeted manner, and in these areas, for example, the grid-shaped structure of the load-bearing structural component is not provided. In the known thermal management module, it is usually designed as a fully enclosed plastic injection molding geometry. Therefore, a relatively large projected area is obtained relative to the component volume, which inevitably leads to the need for an injection molding machine group capable of manufacturing such large components in the process of manufacturing such a thermal management module. The large area leads to a large clamping force of the machine, which leads to high investment costs and therefore high component costs. In contrast, according to the load-bearing structural component of the present invention, the area that does not perform a fluid function can be preferably designed as a grid. Therefore, compared with the prior art, the size of the injection molding machine used to manufacture the thermal management module or its load-bearing structural component can also be reduced. Likewise, when producing the injection-molded load-bearing structural component of the thermal management module, the use of material can be reduced compared to the prior art, and deformations of the component can also be reduced compared to the large-volume injection-molded geometries of the prior art. Since the thermal management module is preferably arranged in the engine compartment of the vehicle, siphon regions can also be omitted or at least reduced, so that no accumulation of dirt or splash water can occur through the grid-like regions of the load-bearing structural component, since dirt and splash water can flow out unhindered through the grid-like regions of the load-bearing structural component.

[0026] In addition, by providing a grid-like area on the load-bearing structural component, its stiffness can be increased or changed locally in a targeted manner. In this way, welds arranged in particular on or inside the load-bearing structural component, such as welds between at least one load-bearing structural component and at least one cover element, can be mechanically unloaded in a targeted manner. By means of the grid-like area on the load-bearing structural component, a certain elasticity and thus component deformation can be allowed in a targeted manner in areas of the load-bearing structural component that are not critical for its function and are far from the welds. In this way, extreme load conditions, such as impact loads when a vehicle passes under bad road conditions or curbs, can be prevented from causing damage to the functional area of ​​the load-bearing structural component of the thermal management module, and thus remain intact. The original shape of the grid-like area of ​​the load-bearing structural component may change under the action of force, for example, the original square may become a rhombus when deformed. The preferred stiffness-optimized area can therefore make partial sections or areas of the load-bearing structural component designed to be softer, thereby avoiding harmful stresses on the functional area. In certain areas, for example, it may be necessary or desirable to have particularly high stiffness. Functionally detrimental loads can be moved away from sensitive areas of the load-bearing structural component and thus away from the thermal management module, such as weld seams and seals, and other functional areas in which components such as at least one pump device and at least one valve are arranged or present.

[0027] By providing grid-like areas on the load-bearing structural component, different temperature influences can also be well withstood. These areas can move by slight deformation without cracking, thereby preventing damage to the load-bearing structural component. The grid-like areas of the load-bearing structural component optimize the thermal management through the ambient air, so that partial sections of the thermal management module can be targeted by the ambient air to flow in order to absorb heat from it or transfer heat to the ambient air. The heat exchange or thermal insulation performance of some functional areas of the thermal management module can also be changed by the characteristics of the grid-like area, that is, the ratio of the crossbeams to the openings in the grid-like area. Therefore, by providing at least one grid-like area, the load-bearing structural component of the thermal management module and the entire module housing can be thermally isolated in certain areas. The load-bearing structural component can also be thermally connected in other areas, especially those areas that are not separated by the grid-like area. The heat exchange and insulation of some functional areas of the thermal management module can be changed by the design of the grid-like area, that is, the ratio of the crossbeams to the openings that form the grid-like area.

[0028] In addition, the grid-like area of ​​the load-bearing structural component allows the manufacture of the actual undercut functional area of ​​the load-bearing structural component to be simplified by alternating immersion of the injection mold halves in the injection molding process, which can be achieved only by the opening and closing movement of the injection mold. Compared with the manufacture of large-volume injection molding geometries of thermal management modules in the prior art, it can also work at lower pressures. In addition, a sufficient pressure holding effect can be ensured in the injection molding process to avoid the appearance of air bubbles, especially in the grid-like area of ​​the manufactured load-bearing structural component, so that no defects are left after the injection molding material cools and shrinks, especially in the grid-like area of ​​the load-bearing structural component. In addition, a more uniform material distribution can be achieved, and compared with the injection molding geometry of the thermal management module of the prior art, less material is required to manufacture the thermal management module of the present invention or its load-bearing structural component, so that its cost can also be reduced compared with the prior art.

[0029] It is further advantageous that the load-bearing structural component can have an acoustically isolated area within its structure to avoid transmitting sound waves through the thermal management module into the vehicle in which it is installed. This acoustic isolation can be achieved by a targeted stiffness design, resulting in a shift in the natural frequency. The load-bearing structural component can have an acoustically isolated area, in particular, by a targeted stiffness design in its grid-like area, so that the shift in the natural frequency in these places can lead to acoustic isolation. In addition, damping material can be added to the grid-like area of ​​the load-bearing structural component and / or grooves can be arranged in a targeted manner in the grid-like area of ​​the structural component and / or other acoustic isolation measures can be taken. In addition, damping material can be provided in the vehicle for the fixing points or fixing areas of the thermal management module or its load-bearing structural component so as to achieve acoustic isolation in these places. For example, a bolt connection can be made in the fixing point area of ​​the load-bearing structural component of the thermal management module in the vehicle, and a damping material, such as a foam material, can be arranged in the bolt connection area or the fixing point area. This helps to reduce the propagation of structure-borne sound. Therefore, the thermal management module or its load-bearing structural component can also be partially composed of different materials, thereby forming a two-component component. In order to achieve acoustic decoupling, as mentioned above, foam material or other damping material can be provided, or it can be covered or partially covered with damping material. Therefore, various acoustic decoupling designs can be provided. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] In order to explain the present invention in more detail, the embodiments of the present invention will be described in detail below with reference to the accompanying drawings. These drawings are as follows:

[0031] Figure 1 is a top view of a thermal management module according to a first embodiment of the present invention,

[0032] Figure 1a is based on Figure 1 A first side view of a thermal management module,

[0033] Figure 1b is based on Figure 1 A second side view of the thermal management module,

[0034] Figure 1c is based on Figure 1 A bottom view of the thermal management module and thus a top view of its cover element,

[0035] Figure 2a is based on Figure 1 A perspective top view of a load-bearing structural component according to the invention of a thermal management module,

[0036] Figure 2b is based on Figure 1 A perspective top view of a cover element according to the invention of a thermal management module,

[0037] Figure 2c is based on Figure 2b A perspective bottom view of the cover element,

[0038] Figure 2d is based on Figure 2a A perspective bottom view of the load-bearing structural component,

[0039] Figure 3 is a longitudinal section through a module housing according to the invention in the region of a fluid connection of a thermal management module, the module housing having a load-bearing structural component and a cover element of a thermal management module according to the invention,

[0040] Figure 4a is a perspective detail view of a load-bearing structural component of a thermal management module according to the invention in the region of two adjacent fluid connections of the thermal management module,

[0041] Figure 4b is relative to Figure 4a The view in the perspective view of the load-bearing structural component is rotated 90°.

[0042] Figure 4c is based on Figure 4a along Figure 4b A longitudinal section through the load-bearing structural component along line AA,

[0043] Figure 5a is a perspective detail view of another embodiment of a load-bearing structural component of a thermal management module according to the invention,

[0044] Figure 5b is relative to Figure 5a The view in the perspective view of the load-bearing structural component is rotated 90°.

[0045] Figure 5c is based on Figure 5a along Figure 5b A longitudinal section through the carrier structure component along the line BB in FIG. 1 , wherein one of the two fluid connections is formed in the carrier structure component and the other fluid connection is two-part and has a receiving section formed in the carrier structure component and a fluid connection section formed in the cover element and inserted into the receiving section, and

[0046] Figure 6 It is a perspective detail view of the injection mold in the region of three bottom slides during a demolding process in which one of the bottom slides collides with another adjacent bottom slide when demolding a fluid connection. DETAILED DESCRIPTION

[0047] Figure 1 to Figure 2d A thermal management module 1 is shown, which has a module housing 10 consisting of a load-bearing structural component 2 and a cover element 3. The load-bearing structural component 2 and the cover element 3 are both hollow shapes or shell shapes, in particular produced by injection molding. The respective hollow shapes or shell shapes can be particularly clearly seen from Figure 2c and Figure 2d The cover element 3 has different shapes in its surface extension, i.e., length and width extension, as well as height extension, and thus in the x-axis, y-axis and z-axis directions, which can be seen particularly clearly from Figure 2b . Here, it has cantilevered sections, sections set back relative to these sections, and flat sections. Due to this multi-dimensional shaping, the cover element 3 is inserted into the load-bearing structural component 2 from its open bottom side 20. In this example, the cover element 3 has a substantially flat cantilevered edge 30 for connecting the load-bearing structural component 2 to the cover element 3. This can be seen in particular from the Figure 3 . As can be seen particularly clearly there, the supporting structural component 2 is attached to the edge via its end face 21 of the surrounding outer wall 22. The surrounding outer wall 22 of the supporting structural component 2 can be connected to the cantilevered surrounding edge 30 of the cover element 3 in a materially fitting manner in the region of its end face 21 by welding, in particular laser welding. In order to prevent accidental leakage of temperature control medium in the connection region between the supporting structural component 2 and the cover element 3, a materially fitting connection is preferably provided between the two. Therefore, after the materially fitting connection, for example by welding, a surrounding connection or weld seam 11 can be provided around the module housing 10, as shown in FIG. Figure 3 as shown in .

[0048] like Figure 3As shown, the multi-dimensional shape of the cover element 3 extends particularly well into the interior 23 of the hollow or bowl-shaped load-bearing structural component 2. After the cover element 3 has been inserted into the load-bearing structural component 2, the outer side 33 of the surrounding outer wall 32 of the cover element 3 abuts against the inner side 24 of the surrounding outer wall 22 of the load-bearing structural component 2. The gap between the outer side 33 of the surrounding outer wall 32 of the cover element 3 and the inner side 24 of the surrounding outer wall 22 of the load-bearing structural component 2 can be very small, in particular in the range of tenths of a millimeter. In particular, a clearance fit can be provided here between the surrounding outer wall 32 of the cover element 3 and the surrounding outer wall 22 of the load-bearing structural component 2.

[0049] Between the top 31 of the cover element 3 pointing toward the load-bearing structural component 2 and the inner side 25 of the adjacent shell-like load-bearing structural component 2, a cavity remains, which forms the fluid channel 4. Figure 3 The multi-dimensionally different shapes of the top 31 of the cover element 3, including the convex or cantilevered sections and the concave or groove-shaped sections, may lead to different flow cross sections of the resulting fluid channel 4 in this area. Figure 3 A groove 34 formed on the top 31 of the cover element 3 can be seen in FIG. In the region of the groove 34, the flow cross section d of the temperature control medium flowing in the module housing 10 can be seen. 34 The flow cross section d in the region of the groove 34 34 Here, the flow cross section d in the fluid connection 58 is substantially 54 The flow cross section between the top 31 of the cover element 3 and the inner side 25 of the adjacent shell-shaped load-bearing structural component 2 can be smaller than the flow cross section d outside the recess 34, in particular in a protruding or cantilevered section of the cover element 3. 54 .

[0050] Especially from Figure 2b and 2c It can be seen that the cover element 3 is formed as a single part. In principle, a multi-part cover element or a plurality of individual cover elements can also be provided and connected to the supporting structural component 2. In addition, in particular Figure 1c It can be seen that the cover element 3 extends only in the area of ​​the fluid channels 4a to 4e to be formed or already formed. Therefore, the cover element 3 has only such a shape so as to cover the supporting structure component 2 accordingly in the area of ​​the fluid channels 4a to 4e to be formed or already formed. The remaining area of ​​the supporting structure component 2 is not covered by the cover element 3 or is only covered by the connecting section. Therefore, the cover element 3 has an internal through hole 35 and has corresponding multi-dimensional shaping around the through hole to form different flow cross sections of the fluid channels 4a to 4e, which are formed between the inside of the module housing 10 after the cover element 3 and the supporting structure component 2 are fitted.

[0051] like Figure 2bAs shown, connecting sections 37, 137, 237, 337 are arranged between the multi-dimensionally shaped sections 36, 136, 236, 336, 436 of the cover element 3. The connecting sections are each designed as a flat beam-like structure. Figure 2c This is particularly evident in the bottom view of the cover element 3. If, instead of a single-part cover element 3, a multi-part cover element or a plurality of cover elements 3 are used and connected to the load-bearing structural component 2, a separation between the individual cover elements can or may be proposed in the area of ​​these connecting sections 37, 137, 237, 337, in particular in the area of ​​two large-area connecting sections 37, 137. However, in order to provide the maximum possible rigidity or surface rigidity of the cover element 3, the cover element is preferably single-part. As a result, the entire module housing 10 of the thermal management module 1, which is composed of the load-bearing structural component 2 and the cover element 3, also has a great surface rigidity. As Figure 2b and 2c As shown in detail in FIG. 1 , the arrangement of a one-part cover element has also proven to be additionally advantageous with regard to the durability of the weld seam 11. The weld seam 11 can be, for example, Figure 1a and 1b , are located in one plane. If a multi-part cover element or a plurality of cover elements are provided, it is usually possible or provided that the cover element or the multi-part cover element is welded to the supporting structural component 2 on a plurality of levels.

[0052] Especially from Figure 1c It can be seen from the bottom view of the thermal management module 1 shown that the supporting structure component 2 has a grid-like area 26 in the area of ​​the through-hole 35 of the cover element 3. This area is used for thermal decoupling, wherein the grid-like area 26 is formed by crossbeams 126, 127 and openings 128 retained therebetween. The angle at which the crossbeams 126, 127 intersect each other can be a right angle or an angle different from a right angle. A grid structure is formed by the intersecting crossbeams 126, 127 together with the openings 128 surrounded by the crossbeams. By means of the crossbeams 126, 127 and the openings 128, heat conduction on the surface of the supporting structure component 2 can be interrupted, thereby achieving thermal decoupling of the various areas of the supporting structure component 2 that form the fluid channels 4a to 4e together with the cover element 3. The sections 40, 41, 42, 43, 44 of the supporting structure component 2 for forming the fluid channels 4a, 4b, 4c, 4d, 4e can be seen particularly clearly from Figure 2d It can be seen here that the sections 40, 41, 42 are separated from each other by partition walls 45, 46, respectively, while the sections 43, 44 are formed separately. Figure 2d As further shown, a relatively large gap or distance is left between the section 43 and the section 42 or section 44. These are the regions in which the cover element 3 of the connecting sections 37 and 137 is arranged, so that the cover element 3 also has sufficient stability and rigidity in this region.

[0053] like Figure 2d It can further be seen that the load-bearing structural component 2 has three integrally formed fixing ears 29, 129, 229. These are used to fix the thermal management module 1 to the vehicle or the vehicle body. In addition to such fixing ears, other fixing devices or other fixing points can also be provided on the module housing 10 or in particular on the load-bearing structural component 2.

[0054] like Figure 1 , 1a, 1b and 2a in particular, the load-bearing structural component 2 has a plurality of fluid connections, a portion of which, namely the fluid connections 50, 51, 52, 53, 54, 55, 56, 57, 58, extend along the height extension h direction of the shell-like load-bearing structural component 2, while the fluid connections 59, 60, 61 extend approximately perpendicularly thereto on the outside of the load-bearing structural component 2 or protrude outwardly therefrom. Hoses or pipes can be connected to the fluid connections 50 to 61, so that these media pipes are fluidically connected to the temperature control circuit of the vehicle or its sub-circuits. Therefore, each supply and return flow of such a sub-circuit of the vehicle temperature control circuit is respectively connected to a corresponding fluid connection. Therefore, the temperature control medium can enter the corresponding fluid channels 4a, 4b, 4c, 4d, 4e in the module housing 10 of the thermal management module through the corresponding fluid connections and flow out of the module housing 10 or the thermal management module 1 through the corresponding fluid connections. In order to transport the temperature control medium through the thermal management module or the module housing 10, a pump device 5, 6 can be installed on the load-bearing structural component 2 of the module housing 10 of the thermal management module 1. Figure 1c In order to be able to arrange two pump devices 5, 6 or an appropriate number of pump devices or components generally used for conveying temperature control media on the supporting structural component 2 of the module housing 10 of the thermal management module 1, the supporting structural component 2 is provided with two connecting sections 27, 28 for this purpose, which are suitable for the installation and connection of the pump devices 5, 6. These connecting sections 27, 28 are as shown. Figure 2a As shown, or as Figure 1 and 1c The pump devices 5, 6 shown are particularly clearly shown on the connecting section, are respectively located in the region of the fluid channel and are arranged accordingly in the sections 40, 41, 42, 43, 44 of the supporting structural component 2 designed for it. In addition, the supporting structural component 2 includes two connecting sections 70, 80 for connecting two valves 7, 8 as components for mass flow control, which can also be mounted on the supporting structural component 2 of the module housing 10 of the thermal management module 1. The corresponding connecting sections 70, 80 or valves 7, 8 can be particularly clearly seen from Figure 1 or Figure 2a It can be seen that the connecting sections 70 , 80 are respectively arranged in the branching area of ​​the fluid channel inside the module housing 10 , so as to distribute the mass flow of the temperature control medium to the various fluid connection devices 50 to 61 accordingly.

[0055] in particular Figure 2a , but can also be obtained from Figure 1 As can be seen in FIG. 5 , some fluid connections 50 to 61 are arranged closely adjacent to each other. Since the module housing or its supporting structural component 2 and the cover element 3 are made of plastic by injection molding, when the individual fluid connections are directly molded in the supporting structural component, Figure 6 There, three fluid connection devices 62, 63, 64 are arranged side by side in close proximity. Figure 6 These devices are also moved in the injection mold represented by its bottom slides 90, 91, 92, which require sufficient space in the opening direction. Figure 6 It can be seen that when demolding the manufactured, i.e. injection-molded, load-bearing structural component 2, the bottom slide 91 collides with the fluid connection device 63, because the bottom slide 91 is located between the two injection-molded fluid connections 62, 63 and must be moved away from the device in order to demold the chamfer of the retaining contour on the fluid connection device 62. In the process, it obviously collides with the fluid connection device 63 (see arrow P1), because the distance between the fluid connection device 62 and the fluid connection device 63 is too small to be demolded. Such a collision will at least damage the fluid connection device 63, so that the load-bearing structural component 2 cannot be demolded without damage in the area of ​​the fluid connections 62 and 63.

[0056] To solve this problem, the fluid connection device 62 is designed as two parts. Figure 5a , 5b and 5c. Therefore, the fluid connection device 62 is composed of an annular receiving section 620 formed in the load-bearing structural component 2 and a fluid connection section 621 formed in the cover element 3. Figure 5c As shown, as part of the cover element 3, the fluid connection section 621 is inserted into the receiving section 620 in the load-bearing structural component 2. During the injection molding process of the load-bearing structural component, the fluid connection device 63 and the receiving section 620 can be easily demoulded because the bottom slide 91 no longer collides with the fluid connection device 63. The design of the receiving section 620 is significantly shorter than the fluid connection device 63, which can also be seen from Figure 5a , 5c and Figure 4a , 4c, it can be seen that the two fluid connection devices 62, 63 are integrally formed. The bottom slider used to form the fluid connection device 63 can be easily removed from the receiving section 620 when the fluid connection device 63 is demoulded without collision.

[0057] In order to obtain a tight connection between the receiving section 620 and the fluid connection section 621 inserted therein, a sealing element 622 is provided between them, which can also be obtained from Figure 5c Although Figure 6Compared to the injection mold shown, the injection mold is more complex, because the receiving section 620 must be formed separately on the load-bearing structural component 2, and the fluid connection section 621 must be formed separately on the cover element 3, so that not only the corresponding fluid connection device is formed on the load-bearing structural component 2, but through this two-part design of one or more fluid connections, here the fluid connection device 62, a large amount of space can be obtained, in which a large number of fluid connections can be arranged in a limited space. Thus, multiple sub-circuits of the temperature control circuit of the vehicle can be connected to the thermal management module.

[0058] In addition to the embodiment variants of the thermal management module for managing the mass flow of a temperature control medium of at least one temperature control circuit in a vehicle described above and shown in the figures, many other variants can also be provided, in particular any combination of the above features, wherein the thermal management module comprises at least one module housing, which has at least one load-bearing structural component and at least one cover element, wherein the at least one load-bearing structural component and the at least one cover element are connected to each other in a fluid-tight manner and at least one fluid channel is formed as a fluid path in the interior of the module housing. The fluid path or at least one fluid channel in the interior of the module housing is in fluid connection with a fluid connection device protruding outward from the module housing or can be in fluid connection with these devices.

[0059] Reference numerals

[0060] 1 Thermal Management Module

[0061] 2 Load-bearing structural components

[0062] 3 Cover element

[0063] 4 Fluid channels

[0064] 4a Fluid channel

[0065] 4b Fluid channel

[0066] 4c Fluid channel

[0067] 4d Fluid Channel

[0068] 4e Fluid Channel

[0069] 5 Pump device

[0070] 6 Pump unit

[0071] 7 Valves

[0072] 8 Valves

[0073] 10 Module housing

[0074] 11 Weld

[0075] 20 Open bottom side

[0076] 21 End face

[0077] 22 Around the outer wall

[0078] 23 Interior

[0079] 24 22 inside

[0080] 25 Inside

[0081] 26 Grid Area

[0082] 27 Connection segment

[0083] 28 Connection segment

[0084] 29 Fixing ears

[0085] 30 Cantilever around edge

[0086] 31 Top

[0087] 32 Around the outer wall

[0088] 33 32 outside

[0089] 34 Grooves

[0090] 35 Through Hole

[0091] 36 Multi-dimensional forming section

[0092] 37 Connection segment

[0093] 40 sections

[0094] 41 Sections

[0095] 42 Sections

[0096] 43 Sections

[0097] 44 Sections

[0098] 45 Partition Wall

[0099] 46 Partition Wall

[0100] 50 Fluid connection device

[0101] 51 Fluid connection device

[0102] 52 Fluid connection device

[0103] 53 Fluid connection device

[0104] 54 Fluid connection device

[0105] 55 Fluid connection device

[0106] 56 Fluid connection device

[0107] 57 Fluid connection device

[0108] 58 Fluid connection device

[0109] 59 Fluid connection device

[0110] 60 Fluid connection device

[0111] 61 Fluid connection device

[0112] 62 Fluid connection device

[0113] 63 Fluid connection device

[0114] 64 Fluid connection device

[0115] 70 Connection segment

[0116] 80 Connection segment

[0117] 90 Bottom Slider

[0118] 91 Bottom Slider

[0119] 92 Bottom Slider

[0120] 126 Beam

[0121] 127 Beam

[0122] 128 Opening

[0123] 129 Fixed ear

[0124] 136 Multi-dimensional Forming Section

[0125] 137 Connection segment

[0126] 229 Fixed ear

[0127] 236 Multi-dimensional Forming Section

[0128] 237 Connection segment

[0129] 336 Multi-dimensional Forming Section

[0130] 337 Connection segment

[0131] 436 Multi-dimensional Forming Section

[0132] 620 Receive segment

[0133] 621 Fluid connection section

[0134] 622 Sealing element

[0135] d 31Flow diameter at 31

[0136] d 34 Flow diameter at 34

[0137] h Height extension

[0138] P1 Arrow / Collision

Claims

1. A thermal management module (1) for managing the mass flow of a temperature control medium of at least one temperature control circuit in a vehicle, wherein: The thermal management module (1) comprises at least one module housing (10), at least one fluid connection device (50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64) and at least one fluid path inside the module housing (10), characterized in that the module housing (10) comprises at least one load-bearing structural component (2) and at least one cover element (3), wherein the at least one load-bearing structural component (2) and the at least one cover element (3) can be connected to each other or are connected, and at least one fluid channel (4, 4a, 4b, 4c, 4d, 4e) is formed therebetween as the fluid path.

2. The thermal management module (1) according to claim 1, characterized in that: The at least one supporting structural component (2) is designed to be able to arrange or have arranged or integrated therein at least one component (5, 6) for conveying a temperature control medium and at least one component (7, 8) for mass flow regulation, in particular at least two components (5, 6) for conveying a temperature control medium and at least one component (7, 8) for mass flow regulation.

3. The thermal management module (1) according to claim 2, characterized in that: The at least one supporting structural component (2) is designed so that at least one of the components (5, 6) for conveying the temperature control medium and at least one of the components (7, 8) for mass flow control can be mounted or have been mounted on the same side of the at least one supporting structural component (2).

4. The thermal management module (1) according to claim 1, 2 or 3, characterized in that: At least one of the supporting structural components (2) and at least one of the cover elements (3) are designed as a single part or multiple parts, in particular as multiple parts, in particular as multiple parts and can be or are connected to each other in a materially fitting manner, in particular are connected to each other in a materially fitting manner by laser welding.

5. The thermal management module (1) according to any one of the preceding claims, characterized in that The connection area where at least one of the cover elements (3) and at least one of the supporting structural components (2) are connected is located on the same plane.

6. Thermal management module (1) according to any one of the preceding claims, characterized in that The cover element (3) is designed in multiple parts, and the multiple-part cover element (3) can be connected or is connected to at least one of the supporting structural components (2) in multiple planes.

7. Thermal management module (1) according to any one of the preceding claims, characterized in that At least one of the cover elements (3) is at least partially designed in a groove shape to form different flow cross sections (d ... 31 , d 34 ).

8. Thermal management module (1) according to any one of the preceding claims, characterized in that In order to optimize the flow of the temperature control medium flowing in at least one of the fluid channels (4, 4a, 4b, 4c, 4d, 4e) inside the thermal management module (1), at least one of the cover elements (3) is shaped differently in multiple dimensions in its cross section, in particular having a protruding or cantilevered section and a recessed or groove-shaped section (34) in the direction toward the supporting structural component (2).

9. Thermal management module (1) according to any one of the preceding claims, characterized in that At least one of the fluid connection devices (50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64) is arranged or formed on at least one of the load-bearing structural components (2) and / or at least one of the cover elements (3).

10. The thermal management module (1) according to claim 9, characterized in that At least one of the fluid connection devices (50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64) is composed of at least one receiving section (620) formed in at least one of the load-bearing structural components (2) and at least one fluid connection section (621) formed in at least one of the cover elements (3) and insertable or inserted into at least one of the receiving sections (620).

11. The thermal management module (1) according to claim 10, characterized in that: At least one sealing element (622) is provided for fluid-sealing the connection between the receiving section (620) and the fluid connecting section (621), and can be provided or is provided between them.

12. Thermal management module (1) according to any one of the preceding claims, characterized in that At least one of the load-bearing structural components (2) is at least partially grid-shaped, in particular no cover element (3) is arranged in (multiple) grid-shaped areas (26) of at least one of the load-bearing structural components (2) or at least one of the cover elements (3) extends outside of at least one of the grid-shaped areas (26).

13. A vehicle having at least one temperature control circuit for temperature control of vehicle components, in particular at least one battery and at least one electronic component, wherein at least one thermal management module is provided for managing the mass flow of a temperature control medium in at least one of the temperature control circuits, characterized in that: The thermal management module is a thermal management module (1) according to any one of the preceding claims.

Images