Replaceable integrated cooling liquid module
By designing an integrated coolant module system with multiple flow channels and flow connectors, the problem of poor vehicle design adaptability in existing technologies is solved, packaging flexibility and tooling complexity are reduced, and cross-platform versatility and BOM management efficiency are improved.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-11-08
- Publication Date
- 2026-03-24
AI Technical Summary
Existing integrated coolant module systems are difficult to adapt to various vehicle designs, resulting in complex and expensive piping configurations and vehicle-specific solutions, which increases vehicle complexity and reduces the availability of alternatives for cross-platform common components.
An integrated coolant module system was designed, including multiple flow channels and flow connectors, a body manufactured using additive manufacturing and molding processes, and multiple pump flow ports and adapters, providing fluid connectivity and packaging flexibility to adapt to the connection mechanization requirements of different vehicle platforms.
This achieves greater packaging flexibility and reduced tooling complexity for the coolant module, reduces vehicle part proliferation, improves cross-platform versatility and BOM management efficiency, and reduces vehicle complexity.
Smart Images
Figure CN121726587A_ABST
Abstract
Description
Technical Field
[0001] This disclosure relates to modules for fluid distribution in vehicles. Background Technology
[0002] For vehicles, including battery electric vehicles, an integrated coolant module (ICM) defines a system for distributing fluids (such as coolant) to remove heat from vehicle systems, including the battery system, and to distribute that heat to heat-generating components, including the radiator. In systems without an ICM, all heat-generating components are distributed throughout a compartment under the vehicle's hood. This results in a complex and expensive piping configuration. It is often difficult to apply a universal coolant distribution solution to multiple vehicle designs in terms of packaging, flexible connections, and size. Given current module designs, when an ICM solution is required, it is vehicle-specific, which increases vehicle complexity and reduces the availability of cross-platform, common component alternatives.
[0003] Therefore, while current systems and methods for providing coolant distribution via ICM have achieved their intended purpose, a new and improved system and method is still needed to allow ICM to be used in a variety of different vehicle designs. Summary of the Invention
[0004] According to several aspects, an integrated coolant module (ICM) system includes a module having a body. The body has multiple flow channels including a first flow channel, a second flow channel, and a third flow channel. Each of a plurality of flow connectors is fixed to a respective flow channel in the plurality of flow channels. The plurality of flow connectors in the first flow channel includes a first flow connector, a second flow connector, a third flow connector, and a fourth flow connector. The first flow channel provides fluid communication between at least two of the first, second, third, and fourth flow connectors.
[0005] In another aspect of this disclosure, the coolant pump assembly has a plurality of pump flow ports, wherein one of the plurality of flow ports is connected to one of a plurality of flow connectors.
[0006] In another aspect of this disclosure, the coolant pump assembly includes a pump body that defines a housing for receiving the coolant pump, which provides flow distribution of coolant via a plurality of pump flow ports.
[0007] In another aspect of this disclosure, the plurality of pump flow ports include a discharge flow port, a first inlet flow port, a second inlet flow port oriented substantially at 90 degrees to the first inlet flow port, and a third inlet flow port oriented substantially at 90 degrees to the second inlet flow port.
[0008] In another aspect of this disclosure, a coolant pump assembly defines a first coolant pump assembly having one of a first inlet flow port, a second inlet flow port, and a third inlet flow port, one of which is mounted on any one of a plurality of flow channels of the module.
[0009] In another aspect of this disclosure, a coolant pump assembly defines a first coolant pump assembly having a third inlet flow port that is plastically welded to a second flow connector, and closing the first inlet flow port and the second inlet flow port.
[0010] In another aspect of this disclosure, the module system includes a second coolant pump assembly mounted on one of a plurality of flow channels of the module that are different from those of the first coolant pump assembly.
[0011] In another aspect of this disclosure, the plurality of flow connectors of the second flow channel include a fifth flow connector, a sixth flow connector, a seventh flow connector, and an eighth flow connector.
[0012] In another aspect of this disclosure, the plurality of flow connectors of the third flow channel include a ninth flow connector, a tenth flow connector, an eleventh flow connector, and a twelfth flow connector.
[0013] In another aspect of this disclosure, the coolant system distributes coolant to the vehicle's coolant supply system via a module, and thereby to the vehicle's battery system.
[0014] According to several aspects, a vehicle integrated coolant module system includes a module having a body for distributing coolant to a cooling system. Each of a plurality of flow channels in the body is fluidly isolated from the other flow channels in the plurality of flow channels, including a first flow channel, a second flow channel, and a third flow channel. A plurality of flow connectors include: a first flow connector, a second flow connector, a third flow connector, and a fourth flow connector for the first flow channel, each defining four fluid openings in the first flow channel; a fifth flow connector, a sixth flow connector, a seventh flow connector, and an eighth flow connector for the second flow channel, each defining four fluid openings in the second flow channel; and a ninth flow connector, a tenth flow connector, an eleventh flow connector, and a twelfth flow connector for the third flow channel, each defining four fluid openings in the third flow channel. A first coolant pump assembly includes a plurality of pump flow ports, one of which is connected to one of the plurality of flow connectors in the first, second, and third flow channels to generate a coolant flow through one of the first, second, and third flow channels.
[0015] In another aspect of this disclosure, the first flow channel provides fluid communication between at least two of the first flow connector, the second flow connector, the third flow connector, and the fourth flow connector.
[0016] In another aspect of this disclosure, the second coolant pump assembly has a plurality of second coolant pump flow ports, wherein one of the plurality of second coolant pump flow ports is connected to a different flow connector in the first flow channel, the second flow channel, and the third flow channel to which the first coolant pump assembly is connected.
[0017] In another aspect of this disclosure, the flow adapter is defined as a plastic solder adapter for fixed connection with a flow connector.
[0018] In another aspect of this disclosure, the flow adapter defines one of the elbow adapter, transition adapter, and plug adapter.
[0019] In another aspect of this disclosure, the main body is a metallic material manufactured using an additive manufacturing process.
[0020] In another aspect of this disclosure, the main body is a polymer material manufactured using either molding or additive manufacturing processes.
[0021] According to several aspects, a method for distributing vehicle coolant via an integrated coolant module (ICM) system includes: molding a module having a body; integrally forming a plurality of flow channels within the body, including a first flow channel, a second flow channel, and a third flow channel; securing each of a plurality of flow connectors to each of the first, second, and third flow channels, wherein the plurality of flow connectors of the first flow channel includes a first flow connector, a second flow connector, a third flow connector, and a fourth flow connector; providing fluid communication between any two or all of the first, second, third, and fourth flow connectors through the first flow channel; and connecting one of a plurality of pump flow ports of a first coolant pump assembly to one of the plurality of flow connectors of the first, second, or third flow channel to generate a coolant flow cooled through one of the first, second, and third flow channels.
[0022] In another aspect of this disclosure, the method further includes connecting a second coolant pump assembly having multiple pump flow ports to a flow connector that is different from one of the first flow channels, second flow channels, and third flow channels to which the first coolant pump assembly is connected.
[0023] In another aspect of this disclosure, the method further includes collecting coolant dispensed by the first coolant pump assembly and the second coolant pump assembly to a heat exchanger defining a radiator via a coolant return system of the vehicle.
[0024] Further areas of application will become apparent from the description provided herein. It should be understood that these descriptions and specific examples are for illustrative purposes only and are not intended to limit the scope of this disclosure. Attached Figure Description
[0025] The accompanying drawings described herein are for illustrative purposes only and are not intended to limit the scope of this disclosure in any way.
[0026] Figure 1 This is a left front perspective view of a vehicle having an integrated coolant module (ICM) system according to an exemplary aspect;
[0027] Figure 2 yes Figure 1 A top view of an exemplary module of the system;
[0028] Figure 3 yes Figure 2 The top perspective view of the module further illustrates an exemplary adapter for fluid system connection;
[0029] Figure 4 It is used for Figure 2 Top perspective view of an exemplary adapter for the module;
[0030] Figure 5 It is suitable for installation Figure 2 Front perspective view of the coolant pump assembly on the module;
[0031] Figure 6 It has two Figure 5 Top view of the first module system of the coolant pump assembly;
[0032] Figure 7 It has two Figure 5 A top view of the second module system of the coolant pump assembly; and
[0033] Figure 8 It has two Figure 5 Top view of the third module system of the coolant pump assembly. Detailed Implementation
[0034] The following description is merely exemplary in nature and is not intended to limit this disclosure, its application, or its uses.
[0035] refer to Figure 1 An integrated coolant module (ICM) system 10 is provided for vehicle 12. Vehicle 12 may include a battery electric vehicle, a hybrid electric vehicle, and a gasoline or diesel-powered vehicle. Coolant system 14 is used to distribute coolant (e.g., water or a mixture of water and antifreeze) via module 16 of this disclosure. According to several aspects, coolant system 14 may distribute coolant to coolant supply system 18 via module 16, and thereby distribute coolant to vehicle systems including vehicle battery system 20. Vehicle systems require cooling and all coolant may be returned to heat exchanger 24, such as radiator, via coolant return system 22.
[0036] refer to Figure 2And refer again Figure 1 Module 16 includes a body 26. Body 26 may be a polymer material, such as, but not limited to, polyamide or a metal, and may be manufactured using molding or additive manufacturing processes. According to several aspects, module 16 includes a plurality of flow channels, including a first flow channel 28 providing a first flow connector 30, a second flow connector 32, a third flow connector 34, and a fourth flow connector 36. The first flow channel 28 provides fluid communication between any two or all of the first flow connector 30, the second flow connector 32, the third flow connector 34, and the fourth flow connector 36.
[0037] Module 16 also includes a plurality of additional flow channels, including a second flow channel 38 having a fifth flow connector 40, a sixth flow connector 42, a seventh flow connector 44, and an eighth flow connector 46. The second flow channel 38 provides fluid communication between any two or all of the fifth flow connector 40, the sixth flow connector 42, the seventh flow connector 44, and the eighth flow connector 46. An exemplary flow adapter 48 is shown mounted in the eighth flow connector 46, which can provide communication with reference to... Figures 4 to 8 The fluid flow connections of additional components, pipes, or flow fittings are shown and described in more detail.
[0038] Module 16 also includes an additional flow channel, which includes a third flow channel 50 having a ninth flow connector 52, a tenth flow connector 54, an eleventh flow connector 56, and a twelfth flow connector 58. The third flow channel 50 provides fluid communication between any two or all of the ninth flow connector 52, the tenth flow connector 54, the eleventh flow connector 56, and the twelfth flow connector 58. Each of the first flow channels 28, the second flow channel 38, and the third flow channel 50 is in fluid communication with a respective flow connector among the plurality of flow connectors via at least one fluid engagement channel. For example, a fluid engagement channel 60 provides fluid communication from the third flow channel 50 to the tenth flow connector 54.
[0039] Each of the flow channels 28, 38, and 50 is not interconnected with any other flow channel in the same flow channel. Therefore, no fluid flow is provided between any two or more of the flow channels 28, 38, and 50. This allows for the use of independently supplied flow components (including references). Figure 6 , 7 The different flow pumps shown and described in Figures 8 direct the flow to the vehicle system individually.
[0040] refer to Figure 3 And refer again Figure 1 and Figure 2Module 16 may include an adapter for receiving mechanically connected or plastic-welded fittings. In the presented example, the seventh-flow connector 44 may have a concave adapter 62 for receiving a reference. Figure 4 The convex connector is shown and described in more detail. Additionally, a convex adapter 64 is provided for the twelfth flow connector 58 to receive a reference connector. Figure 4 The concave connector is shown and described in more detail.
[0041] refer to Figure 4 And refer again Figures 1 to 3 Examples of adapters used in module 16 include references. Figure 2 The flow adapter 48 shown and described defines a plastic welding adapter for use with, for example, reference numerals. Figure 2 The described first connector 30, second connector 32, third connector 34, and fourth connector 36 are fixedly connected. An elbow adapter 66 includes a plastic solder flange 66a, a convex adapter portion 66b, and an elbow portion 66c. A transition adapter 68 includes a concave tube connector 68a and a convex adapter portion 68b. A plug adapter 70 includes a plastic solder flange 70a, for example, for plastic soldering to one of the connectors, such as referenced in [reference needed]. Figure 2 The first flow connector 30, the second flow connector 32, the third flow connector 34, and the fourth flow connector 36 are described. The plug adapter also includes a protruding plug portion 70 for insertion into the port opening of one of the flow connectors, such as those referenced in [reference needed]. Figure 2 The first-flow connector 30, the second-flow connector 32, the third-flow connector 34, and the fourth-flow connector 36 described are used to permanently close the port opening during installation.
[0042] refer to Figure 5 And refer again Figures 1 to 4 The coolant pump assembly 72 is adapted to be mounted to any flow connector of module 16. Pump body 74 defines a housing that accommodates the flow components of the coolant pump 76, such as an impeller (not shown), and pump body 74 provides coolant flow distribution through a plurality of flow ports including an outlet flow port 78, a first inlet flow port 80, a second inlet flow port 82 oriented substantially 90 degrees to the first inlet flow port 80, and a third inlet flow port 84 oriented substantially 90 degrees to the second inlet flow port 82. Body 74 also provides a mounting surface 85 for releasably securing the coolant pump 76 to the body 74 of coolant pump assembly 72. The orientation of the plurality of flow ports allows coolant pump assembly 72 to be oriented in 90-degree increments on module 16.
[0043] refer to Figure 6 And refer again Figures 1 to 5The first module system 86 includes a module 16 and provides a first coolant pump assembly 72a and a second coolant pump assembly 72b. The first coolant pump assembly 72a is mounted to plastic-weld a third inlet flow port 84 to a second flow connector 32 and to close the first inlet flow port 80 and the second inlet flow port 82. Coolant can enter the first flow connector 30 in the inlet flow direction 88 and exit from the outlet flow port 78 of the first coolant pump assembly 72a in the outlet flow direction 90.
[0044] The second coolant pump assembly 72b is mounted such that the second inlet flow port 82 is plastic-welded to the tenth flow connector 54, and the first inlet flow port 80 and the third inlet flow port 84 are closed. Coolant can flow into the ninth flow connector 52 along the inlet flow direction 92 and out from the outlet flow port 78 of the second coolant pump assembly 72b along the outlet flow direction 94. Notably, in this respect, the outlet flow direction 94 is oriented at approximately 90 degrees relative to the outlet flow direction 90.
[0045] refer to Figure 7 And refer again Figures 1 to 6 The second module assembly 96 is modified from the first module assembly 86 and is adapted to be mounted onto at least one different flow connector of module 16. The first coolant pump assembly 72c is mounted to plastic-solder the second inlet flow port 82 to the third flow connector 34, and to close the first inlet flow port 80 and the third inlet flow port 84. Coolant can enter the second flow connector 32 in the inlet flow direction 98 and exit from the outlet flow port 78 of the first coolant pump assembly 72c in the outlet flow direction 100.
[0046] The second coolant pump assembly 72d is mounted such that the second inlet flow port 82 is plastic-welded to the tenth flow connector 54, and the first inlet flow port 80 and the third inlet flow port 84 are closed. Coolant can flow into the ninth flow connector 52 along the inlet flow direction 102 and out from the outlet flow port 78 of the second coolant pump assembly 72d along the outlet flow direction 104. It is noteworthy that, in this respect, the outlet flow direction 104 is opposite and therefore oriented approximately 180 degrees relative to the outlet flow direction 100.
[0047] refer to Figure 8 And refer again Figures 1 to 7 The third module assembly 106 is modified from the first module assembly 86 and the second module assembly 96 and is adapted to be mounted on at least one different flow connector of module 16. The first coolant pump assembly 72e is mounted to plastic-solder the first inlet flow port 80 to the third flow connector 34 and to close the second inlet flow port 82 and the third inlet flow port 84. Coolant can flow into the second flow connector 32 in the inlet flow direction 108 and out from the outlet flow port 78 of the first coolant pump assembly 72e in the outlet flow direction 110.
[0048] The second coolant pump assembly 72f is mounted such that the first inlet flow port 80 is plastic-welded to the eleventh flow connector 56, and the second inlet flow port 82 and the third inlet flow port 84 are closed. Coolant can flow into the ninth flow connector 52 along the inlet flow direction 112 and out from the outlet flow port 78 of the second coolant pump assembly 72f along the outlet flow direction 114. It is noteworthy that, in this respect, the outlet flow direction 114 is opposite and therefore oriented approximately 180 degrees relative to the outlet flow direction 110.
[0049] The ICM system 10 of this disclosure centralizes the coolant hardware into a single module, eliminating the need for extended coolant lines. The ICM system 10 uses a common ICM backend or module 16 to reduce components and provide efficient encapsulation. The ICM system 10 of this disclosure provides at least three different locations and orientations for mounting the coolant pump module. Combined with fittings and end caps, the ICM system 10 provides at least twenty-four possible component locations from a single module 16 without requiring specialized tools for different vehicle platforms or coolant mechanics.
[0050] Compared to current integrated coolant module concepts, the ICM system 10 disclosed herein offers packaging flexibility and reduces tooling complexity, including reduced tooling diffusion and reduced component diffusion across the vehicle. Packaging flexibility is enhanced by the ability to change port connections and locations as needed to accommodate different types of connection mechanics concepts on different vehicle platforms. Vehicle BOM complexity is also reduced; BOM management (such as components, suppliers, and parts in an automotive assembly plant) is reduced.
[0051] The ICM system 10 disclosed herein offers several advantages. These advantages include: a method for interconnecting coolant modules to place / position ports, six-way valves, coolant pumps, or any coolant hardware at different locations within the modules, thereby providing flexibility in implementing different packaged solutions using a common core module. Designers and vehicle architects can apply the current ICM concept to different vehicle platforms. The ICM module of this disclosure uses current plastic soldering techniques to isolate or open channels on the mainboard, thereby providing additional available coolant branches for the mechanized system as needed.
Claims
1. An integrated coolant module (ICM) system, comprising: Module, the module having a main body; Multiple flow channels are integrally formed with the main body, and the multiple flow channels include a first flow channel, a second flow channel, and a third flow channel; Multiple flow connectors, wherein each flow connector is fixed to a specific flow channel in the multiple flow channels; The plurality of flow connectors in the first flow channel include a first flow connector, a second flow connector, a third flow connector, and a fourth flow connector; and The first flow channel provides fluid communication between at least two of the first flow connector, the second flow connector, the third flow connector, and the fourth flow connector.
2. The integrated coolant module (ICM) system according to claim 1 further includes a coolant pump assembly having multiple pump flow ports, wherein, The plurality of pump flow ports are connected one-to-one with the plurality of flow connectors.
3. The integrated coolant module (ICM) system according to claim 2, wherein, The coolant pump assembly includes a pump body that defines a housing for receiving the coolant pump, which provides coolant flow distribution via a plurality of pump flow ports.
4. The integrated coolant module (ICM) system according to claim 3, wherein, The plurality of pump flow ports include a discharge flow port, a first inlet flow port, a second inlet flow port oriented substantially at 90 degrees to the first inlet flow port, and a third inlet flow port oriented substantially at 90 degrees to the second inlet flow port.
5. The integrated coolant module (ICM) system according to claim 4, wherein, The coolant pump assembly defines a first coolant pump assembly having one of a first inlet flow port, a second inlet flow port, and a third inlet flow port, wherein one of the first inlet flow port, the second inlet flow port, and the third inlet flow port is mounted on any one of the plurality of flow channels of the module.
6. The integrated coolant module (ICM) system according to claim 4, wherein, The coolant pump assembly defines a first coolant pump assembly having a third inlet flow port that is plastic-welded to the second flow connector, and closing the first inlet flow port and the second inlet flow port.
7. The integrated coolant module (ICM) system according to claim 5 further includes a module system having a second coolant pump assembly, the second coolant pump assembly being installed in one of a plurality of flow channels on the module, the installation flow channel being the same as the flow channel in which the first coolant pump assembly is installed.
8. The integrated coolant module (ICM) system according to claim 1, wherein, The plurality of flow connectors in the second flow channel include a fifth flow connector, a sixth flow connector, a seventh flow connector, and an eighth flow connector.
9. The integrated coolant module (ICM) system according to claim 8, wherein, The plurality of flow connectors in the third flow channel include a ninth flow connector, a tenth flow connector, an eleventh flow connector, and a twelfth flow connector.
10. The integrated coolant module (ICM) system of claim 1, comprising a vehicle coolant supply system that supplies coolant via one of the plurality of flow channels.