Thermal management module

Abstract

A thermal management module (100) includes a fluid hub (10), at least one fluid pump (30a, 30b), and at least one heat exchanger (20). The fluid hub (10) includes a fluid flow passage and a multi-way valve for defining and regulating a fluid supply to the heat exchanger (20) to configure selective fluid communication between the fluid hub (10) and the heat exchanger (20). A fluid pump (30a, 30b) is used to circulate fluid through the fluid flow passage and the heat exchanger (20) and to configure fluid flow therebetween. The heat exchanger (20) is adapted to cool the fluid received from the fluid pump for circulation through heat-generating components of the vehicle. A heat exchanger (20) on which a fluid pump (30a, 30b) is mounted is mounted on a vehicle, and at least a portion of a fluid hub (10) is supported between the fluid pump (30a, 30b) and the heat exchanger (20).

Description

Technical Field

[0001] This invention relates to a thermal management module, and more specifically, to a thermal management module for controlling fluid flow through a vehicle heat exchanger. Background Technology

[0002] Figure 1 and Figure 2 An assembled and exploded view of the thermal management module 01 is shown. Typically, the thermal management module 01 includes a fluid hub 02, at least one fluid pump 04, at least one vehicle heat exchanger, such as a cooler 06, and a buffer tank 08. Typically, the fluid hub 02 is formed by joining two planar parts 02a and 02b of plastic material by plastic welding, wherein at least one of the planar parts 02a and 02b is configured with a channel that defines a fluid flow path when the first planar part 02a and the second planar part 02b are engaged with each other. Furthermore, the fluid hub 02 is configured with a multi-way valve controlled by a controller to selectively interrupt fluid flow through the internal fluid flow path, thereby defining different cooling circuits and regulating the fluid supply to the vehicle heat exchanger 06 based on requirements. More specifically, the fluid hub 02 is configured with several cooling circuits, through which one or more cooling fluids are directed to achieve different cooling based on requirements, while still maintaining fluid isolation between the cooling fluids flowing through the different cooling circuits. The fluid pump 04 drives flow through the different cooling circuits configured based on the operational configuration of different valves arranged in the fluid hub 02. The fluid hub 02 receives fluid stored in the buffer tank 08 and selectively supplies cooling fluid to different heat exchangers 06 via different cooling circuits configured based on the operation of valves in the fluid hub 02. One of the vehicle heat exchangers is the cooler 06, which is a plate heat exchanger formed by brazing multiple aluminum plates. The first planar portion 02a and the second planar portion 02b of the fluid hub 02 include respective mounting holes 03a and 03b, which are aligned with each other to configure a through hole 03 for mounting the fluid hub 02 to the vehicle frame. The fluid hub 02 also includes mounting holes or perforated posts 03c for mounting the fluid pump 04, vehicle heat exchangers such as the cooler 06, and other electronic components thereon. Typically, the mounting hole 03 receives a damper 03d to prevent vibrations from the vehicle frame from reaching the precision components mounted on the fluid hub 02. In particular, the fluid hub 02 serves as a structural component for mounting the vehicle heat exchanger 06 and the fluid pump 04 thereon.

[0003] However, fluid hubs formed from plastic materials and joined by planar components cannot exhibit sufficient material strength or resistance to withstand the loads of the components mounted on them, and are prone to mechanical failure. More specifically, the plastic welds used to join the planar components of the fluid hub are prone to failure, leading to reliability issues. Furthermore, conventional thermal management modules face encapsulation problems because their various components (such as coolers and fluid pumps) are housed in the limited space of a vehicle environment, resulting in complex fluid flow loops and numerous connections that contribute to pressure drops and losses.

[0004] Therefore, a thermal management module is needed, wherein components exhibiting mechanical strength and capable of withstanding loads are used to mount heavier components, such as fluid pumps and heat exchangers. Furthermore, a reliable and compact thermal management module is needed. Additionally, a thermal management module is needed whose configuration involves a simplified fluid flow loop with fewer connectors, thereby reducing pressure drop through it.

[0005] In this specification, some elements or parameters may be indexed, such as first element and second element. In this case, unless otherwise stated, the index only means to distinguish and name similar but not identical elements. The concept of priority should not be inferred from such an index, as these terms can be switched without departing from the invention. Furthermore, the index does not imply any order in which the elements of the invention are installed or used. Summary of the Invention

[0006] An embodiment of the present invention discloses a thermal management module. The thermal management module includes at least one heat exchanger, a fluid hub, and at least one fluid pump. The fluid hub includes multiple fluid flow paths and a multi-way valve for defining and regulating the fluid supply to the vehicle heat exchanger to configure selective fluid communication between the fluid hub and the heat exchanger. The fluid pump is used to allow fluid flow through the fluid flow paths and the vehicle heat exchanger, and to configure the fluid flow between the fluid hub and the vehicle heat exchanger. The heat exchanger is adapted to cool the fluid received from the fluid pump for flow through heat-generating components disposed in the vehicle. The heat exchanger, on which at least one fluid pump is mounted, is adapted to be installed in the vehicle. Furthermore, at least a portion of the fluid hub is supported between the fluid pump and the heat exchanger.

[0007] Preferably, the heat exchanger is configured with mounting holes for mounting a fluid pump on the heat exchanger.

[0008] Typically, the fluid hub is made of plastic material and includes a collector housing and a dispensing housing that are connected and fluidly communicated with each other.

[0009] Specifically, the collector housing extends along the first direction A and is in fluid communication with the buffer tank.

[0010] More specifically, the collector housing includes openings therein and receives a valve spool. The valve spool is adapted to move within the collector housing to selectively establish or interrupt fluid communication between different openings based on its relative position within the collector housing, thereby configuring fluid flow paths and multi-way valves.

[0011] Specifically, at least a portion of the distribution housing is mounted on the heat exchanger, supported between the fluid pump and the heat exchanger, and the distribution housing is adapted to distribute the fluid it receives from the collector housing to the fluid pump.

[0012] Specifically, the distribution shell includes a first distribution web and a second distribution web extending substantially orthogonal to the first direction A in opposite directions B and C.

[0013] Generally, the first and second distribution webs include a central portion and arms extending radially from the central portion. The central portion is selectively in fluid communication with the collector hub based on the operation configuration of a multi-way valve to supply fluid to a fluid pump.

[0014] Typically, a vehicle heat exchanger is at least one of a cooler, radiator, heater core, and cooler for power electronic devices.

[0015] Specifically, the heat exchanger is an aluminum plate heat exchanger, formed by brazing multiple plates.

[0016] Specifically, the fluid pump is in fluid communication with the fluid hub on one side and with the heat exchanger on the other side.

[0017] More specifically, a fluid pump is a radial pump, which is adapted to receive fluid from a central fluid hub, compress the fluid, and direct the compressed fluid to its periphery.

[0018] According to an embodiment of the present invention, the thermal management module includes two fluid pumps disposed on opposite sides of the heat exchanger.

[0019] More specifically, the first fluid pump is adapted to direct fluid to the heat exchanger, and the second fluid pump is adapted to direct fluid from the fluid hub to the drive unit.

[0020] Typically, the first fluid pump is in fluid communication with the heat exchanger via an outlet and connector formed on the fluid hub.

[0021] Specifically, the buffer tank is adapted to store coolant therein, and when installed in a vehicle, the buffer tank is positioned at the highest point in the vertical direction relative to other components of the thermal management module.

[0022] Typically, the relative movement between the collector housing and the valve core to control fluid flow through the multi-way valve is controlled by the control unit to selectively interrupt fluid flow through the internal fluid flow path.

[0023] Additionally, the thermal management module includes mounting bolts adapted to pass sequentially through aligned mounting holes formed on the fluid pump, fluid hub, and heat exchanger, respectively.

[0024] In addition, the thermal management module includes a bracket for mounting the heat exchanger on the vehicle frame.

[0025] Typically, mounting holes are formed on the bracket to receive mounting bolts for mounting the bracket on the frame, and a damper is placed between the mounting holes and the mounting bolts to prevent frame vibrations from reaching the heat exchanger and the fluid pump mounted on the heat exchanger. Attached Figure Description

[0026] Other features, details, and advantages of the invention may be inferred from the following description of the invention. A more complete understanding of the invention and its many accompanying advantages will become readily apparent when considered in conjunction with the accompanying drawings, by referring to the following detailed description, in which:

[0027] Figure 1 An isometric view of a conventional thermal management module is shown, in which the fluid hub serves as a structural element on which fluid pumps and heat exchangers are mounted;

[0028] Figure 2 It shows Figure 1 An exploded view of a traditional thermal management module;

[0029] Figure 3 An isometric view of a thermal management module according to an embodiment of the present invention is shown, wherein a heat exchanger is used as a structural element on which a fluid pump, a fluid hub and other components are mounted;

[0030] Figure 4 It shows Figure 2 Exploded view of the thermal management module;

[0031] Figure 5 It shows Figure 3 An isometric view of the collector housing of the fluid control unit, wherein the valve core is received within the collector housing;

[0032] Figure 6 It shows Figure 5 An isometric view of the valve core;

[0033] Figure 7 It shows Figure 3 A cross-sectional view of the thermal management module, depicting one of the fluid pumps mounted on the heat exchanger, and an enlarged view depicting at least a portion of the fluid hub supported between the fluid pump and the heat exchanger.

[0034] Figure 8 It shows Figure 2 Another cross-sectional view of the thermal management module depicts the connection between one of the fluid pumps and the heat exchanger.

[0035] Figure 9 A block diagram depicts the interconnections between a fluid pump, a heat exchanger, a fluid hub, and other components in fluid communication with the fluid hub, as well as the flow through them.

[0036] It should be noted that the accompanying drawings disclose the invention in a sufficiently detailed manner for implementation, and the drawings help to better define the invention if necessary. However, the invention should not be limited to the embodiments disclosed in the specification. Detailed Implementation

[0037] The invention is explained using an example of a thermal management system for a vehicle. The thermal management system includes a fluid hub (particularly a coolant hub), at least one fluid pump, and a vehicle heat exchanger (e.g., a cooler). The coolant hub is configured with several cooling circuits, through which one or more cooling fluids are directed to achieve different cooling requirements while maintaining fluid isolation between the cooling fluids flowing through the cooling circuits. The fluid pump drives fluid flow through the different cooling circuits configured based on the operational configuration of different valves in the fluid hub. The thermal management system also includes a fluid pump, particularly a coolant pump for cooling the coolant to be supplied to the vehicle heat exchanger, especially a cooler that extracts heat from the vehicle battery (e.g., the battery of an electric vehicle). The fluid pump exerts stress on the components on which it is mounted due to its weight. According to the invention, the fluid pump and coolant hub are strategically mounted on a robust component of the battery cooling system, such as a cooler mounted on a vehicle frame. The heat exchanger exhibits sufficient mechanical strength to withstand the loads of the fluid pump and other components (e.g., the coolant hub mounted thereon). In addition to cooling the coolant supplied to the battery, the heat exchanger also acts as a structural component bearing the loads of the fluid pump and other components, such as the coolant hub. This configuration of mounting different components on the heat exchanger allows for a compact thermal management system and solves the packaging problem. Although the invention has been explained through an example of a thermal management module for a vehicle, in which the fluid pump is mounted on the heat exchanger, the invention is also applicable to other vehicle and non-vehicle environments where it is necessary to mount various heavier components of the fluid system on structurally robust components of the fluid system to make the fluid system compact and solve packaging problems.

[0038] Figure 3 and Figure 4 Different views of a thermal management module 100 according to an embodiment of the present invention are shown. In particular, Figure 3 An isometric view of the thermal management module 100 is shown. Figure 4An exploded view of the thermal management module 100 is shown. The thermal management module 100 includes a fluid hub, particularly a coolant hub 10, at least one fluid pump 30a, 30b, and at least one heat exchanger 20, wherein the vehicle heat exchanger 20 is at least one of a cooler, a radiator, a heater core, and a cooler for power electronic devices.

[0039] The coolant hub 10 (also referred to as the fluid hub 10) is made of plastic material. The coolant hub 10 includes a collector housing 10a and a distribution housing 10b, which are connected to and in fluid communication with each other. The coolant hub 10 is equipped with multi-way valves to selectively establish and interrupt internal fluid flow paths to define several cooling circuits, through which one or more cooling fluids are directed to achieve different cooling requirements, while still maintaining fluid isolation between the cooling fluids flowing through the cooling circuits.

[0040] The collector housing 10a extends in the first direction A and is in fluid communication with the buffer tank 40. Figure 5 An isometric view of collector housing 10a is shown, in which a valve spool 13 is received within collector housing 10a. Collector housing 10a includes openings 12a and valve spool 13. Openings 12a, or ports, are formed on the periphery of collector housing 10a, and valve spool 13 is received within collector housing 10a. One or more openings 12a are connected to a fluid supply line that supplies coolant fluid to collector housing 10a. Valve spool 13 moves within collector housing 10a to selectively establish or interrupt fluid communication between different openings 12a based on the relative position of valve spool 13 within collector housing 12a, thereby configuring fluid flow paths and multi-way valves. Figure 6 An isometric view of valve core 13 is shown. Valve core 13 includes a shaft 13a connected to a drive to allow rotation of valve core 13 within collector housing 10a. Valve core 13 also includes cutouts 13b formed thereon, which are aligned with different openings 12a based on the angular position of valve core 13 within collector housing 10a to configure internal fluid flow passages that define fluid communication between the respective openings 12a while still maintaining fluid isolation between the internal fluid flow passages.

[0041] This configuration of the valve core 13, which moves relative to the collector housing 10a, defines multiple fluid flow paths and a multi-way valve 14b for defining and regulating the coolant supply to the vehicle heat exchanger 20 to configure selective fluid communication between the coolant hub 10 and the heat exchanger 20. More specifically, the multi-way valve interacts with the fluid flow paths to configure fluid communication between the coolant hub 11 and the heat exchanger based on the operating configuration of the multi-way valve. Typically, fluid flow through the multi-way valve 14b is regulated by controlling the relative movement of the valve core 13 within the collector housing by a control unit. More specifically, the valve core 13 rotates within the collector housing 10a to selectively interrupt fluid flow through the internal fluid flow paths and define the open and closed configuration of the multi-way valve 14b.

[0042] The distribution housing 10b includes a first distribution web 7b and a second distribution web 9b extending substantially orthogonal to opposite directions B and C of the first direction A. The first distribution web 7b and the second distribution web 9b are functionally and structurally identical to each other. More specifically, each of the first distribution web 7b and the second distribution web 9b includes a central portion 11c and an arm 11a extending radially from the central portion 11c. The central portion 11c of the first distribution web 7b and the second distribution web 9b selectively receives fluid from the collector housing 10a and supplies fluid to corresponding fluid pumps 30a and 30b based on a multi-way valve operating configuration. The central portion 11c of each of the first distribution web 7b and the second distribution web 9b defines a housing in fluid communication with the corresponding fluid pumps 30a and 30b. Coolant pressurized in the fluid pump 30a flows from the first fluid pump 30a to the heat exchanger 20 via an outlet 14 formed on the central portion 11c of the first distribution web 7b. At least a portion of the distribution housing 10b, particularly the arms 11a of the first distribution web 7b and the second distribution web 9b, is mounted on opposite sides of the heat exchanger 20 and supported between the heat exchanger 20 and the corresponding fluid pumps 30a and 30b. The distribution housing 10b is adapted to distribute coolant from the collector housing 10a to the fluid pumps 30a and 30b. A buffer tank 40 is adapted to store coolant therein, and when installed in a vehicle, the buffer tank 40 is positioned at its highest point in the vertical direction relative to other components of the thermal management module 100, thereby creating a natural gradient of coolant flow from the buffer tank 40 to the collector tank 10a of the coolant hub 10. The collector housing 10a controls the flow of fluid through it via an internal fluid flow passage and a multi-way valve 14b disposed therein to define multiple cooling circuits. Fluid is guided from the collector housing 10a to the fluid pumps 30a and 30b via the distribution housing 10b. The dispensing housing 10b includes a radially extending arm 11a, on which a mounting hole 11b is formed.

[0043] Fluid pumps 30a and 30b are used to circulate fluid (particularly coolant) through a coolant flow passage and a vehicle heat exchanger 20, and to arrange the coolant flow between the coolant flow passage and the heat exchanger 20. Typically, fluid pumps 30a and 30b are in fluid communication with the coolant hub 10 on one side and with the heat exchanger 20 on the other side. Typically, the thermal management module 100 includes two fluid pumps 30a and 30b mounted on opposite sides of the heat exchanger 20. (Reference) Figure 9 A first fluid pump 30a is configured with a first fluid flow loop C1, wherein the first fluid pump 30a and the fluid hub 10 are part of the first fluid flow loop C1. The first fluid pump 30a is adapted to receive fluid from the fluid hub 10 and the coolant heater 90 and direct the fluid received therefrom to the heat exchanger 20. The fluid undergoes heat exchange in the heat exchanger 20, and the fluid processed in the heat exchanger 20 is directed back to the fluid hub 10 via a rechargeable energy storage system (RESS) (60). The first fluid pump 30a is adapted to direct fluid to the heat exchanger 20 via the heat exchanger 20. A second fluid pump 30b is adapted to direct fluid from the fluid hub 10 to the drive unit 92. More specifically, the first fluid pump 30a is a radial pump adapted to receive fluid at the center from the fluid hub 10 (particularly from the central portion 11C of the distribution web 7b), compress the fluid, and direct the compressed fluid to the periphery of the first fluid pump 30a. The periphery of the first fluid pump 30a is in fluid communication with the heat exchanger 20 via an outlet 14 disposed on the fluid hub 10. Specifically, the distribution web 7b and the outlet 14 are connected to and in fluid communication with the heat exchanger 20 via a connector 70. More specifically, one end of the connector 70 is connected to the outlet 14, and the other end of the connector 70 is connected to the heat exchanger 20, thereby configuring fluid communication between the first fluid pump 30a and the heat exchanger 20. Fluid pumps 30a and 30b include radially extending flanges 32 with mounting holes 32a formed thereon. A second fluid pump 30b configures another fluid flow loop, referred to as a second fluid flow loop independent of the first fluid flow loop, wherein the drive unit and the fluid hub 10 are part of the second fluid flow loop. The second pump 30b directs the fluid received from the fluid hub 10 to the drive unit 92. The fluid supplied to the drive unit 92 returns to the fluid hub 10 via a cryogenic radiator 94, as... Figure 9 As shown.

[0044] As one of the vehicle heat exchangers 20, the heat exchanger 20 is adapted to cool fluid received from fluid pumps 30a and 30b for flow through heat-generating components, such as batteries located in the vehicle (particularly electric or hybrid vehicles). The heat exchanger 20 is adapted to be mounted on a vehicle frame and is provided with mounting holes 22a for mounting the fluid pumps 30a and 30b thereon, wherein at least a portion of the fluid hub 10, particularly the arm 11a, is supported between the fluid pumps 30a and 30b and the heat exchanger 20. The heat exchanger 20 is an aluminum plate heat exchanger and is formed by brazing multiple plates.

[0045] In addition, such as Figure 7 and Figure 8 As shown, the thermal management module 100 includes common mounting bolts 50 adapted to pass sequentially through aligned mounting holes 32a, 11b, and 22a formed in the arms 11a of the fluid pumps 30a and 30b, the distribution webs 7b and 9b of the coolant hub 10, and the heat exchanger 20, respectively. With this configuration, the same bolts 50 used to mount the fluid pumps 30a and 30b above the heat exchanger 20 are used to support the coolant hub 10 between the fluid pumps 30a and 30b and the heat exchanger 20. Therefore, with this configuration, the number of mounting bolts is reduced because separate dedicated bolts are not required to support the coolant hub 10.

[0046] Furthermore, the thermal management module 100 includes a bracket 80 fixed to the heat exchanger 20 for mounting the heat exchanger 20 on the vehicle, particularly on the chassis. According to an embodiment of the invention, the bracket 80 extends from the coolant hub 10, specifically from the distribution housing 10b of the coolant hub 10, which is sandwiched between the fluid pumps 30a, 30b and the cooler 20, and for mounting the cooler 20 on the chassis. Specifically, the bracket 80 is formed with mounting holes 82 receiving mounting bolts 84 for mounting the bracket 80 on the chassis, and a damper 82a is disposed between the mounting holes 82 and the mounting bolts 84 to prevent vibrations from the chassis from reaching the cooler 20 and the fluid pumps 30a, 30b mounted on the cooler 20.

[0047] In no event should the invention be limited to the embodiments specifically described herein, as other embodiments may exist. The invention should be extended to any equivalent means and any combination of technical operations of those means.

Claims

1. A thermal management module (100), comprising: • At least one vehicle heat exchanger (20); • A fluid hub (10) includes multiple fluid flow passages and at least one multi-way valve (14b) for defining and regulating the fluid supply to the vehicle heat exchanger (20) to configure selective fluid communication between the fluid heat exchanger (20) and the fluid hub (10); • At least one fluid pump (30a, 30b) for facilitating fluid flow through the fluid flow passage and the vehicle heat exchanger (20), and configuring fluid flow between the fluid hub (10) and the vehicle heat exchanger (20). The heat exchanger (20) on which the fluid pumps (30a, 30b) are mounted is adapted to be installed on a vehicle, and at least a portion of the fluid hub (10) is supported between the fluid pumps (30a, 30b) and the heat exchanger (20).

2. The thermal management module (100) according to the preceding claim, wherein, The heat exchanger (20) is provided with mounting holes (22a) for mounting the fluid pumps (30a, 30b) on the heat exchanger (20).

3. The thermal management module (100) according to any one of the preceding claims, wherein, The fluid hub (10) is made of plastic and includes a collector housing (10a) and a dispensing housing (10b) that are connected to each other and in fluid communication.

4. The thermal management module (100) according to the preceding claim, wherein, The collector housing (10a) extends in the first direction A and is in fluid communication with the buffer tank (40).

5. The thermal management module (100) according to any one of claims 3 to 4, wherein the collector housing (10a) includes an opening (12a) and receives therein the valve core (13) of the multi-way valve (14b), the valve core (13) being movable within the collector housing (10a) to selectively establish or interrupt fluid communication between different openings (12a) based on the relative position of the valve core (13).

6. The thermal management module (100) according to any one of claims 3 to 5, wherein, At least a portion of the distribution housing (10b) is mounted on the heat exchanger (20) and supported between the fluid pump (30a, 30b) and the heat exchanger (20), and the distribution housing (10b) is adapted to distribute fluid received therefrom from the collector housing (10a) to the fluid pump (30a, 30b).

7. The thermal management module (100) according to any one of claims 4 to 6, wherein, The distribution housing (10b) includes a first distribution web (7b) and a second distribution web (9b), which extend in directions B and C that are substantially orthogonal to the first direction A.

8. The thermal management module (100) according to claim 7, wherein, The first distribution web (7b) and the second distribution web (9b) include a central portion (11c) and an arm (11a) extending radially from the central portion (11c), the central portion (11c) being selectively in fluid communication with the collector hub (10a) based on the operating configuration of the multi-way valve (14b) to supply fluid to the fluid pumps (30a, 30b).

9. The thermal management module (100) according to any one of the preceding claims, wherein, The heat exchanger (20) is a cooler adapted to cool the fluid received from the fluid pumps (30a, 30b) to flow through the heat-generating components disposed in the vehicle.

10. The thermal management module (100) according to any one of the preceding claims, wherein, The fluid pumps (30a, 30b) are in fluid communication with the fluid hub (10) on one side and with the heat exchanger (20) on the other side.

11. The thermal management module (100) according to any one of the preceding claims includes two fluid pumps (30a) and (30b) disposed on opposite sides of the heat exchanger (20).

12. The thermal management module (100) according to claim 10, wherein, A first fluid pump (30a) is configured with a first fluid flow loop, wherein the first fluid pump (30a) and the fluid hub (10) are part of the first fluid flow loop, and the first fluid pump (30a) is in fluid communication with the heat exchanger (20) via an outlet 14 and a connector (70) formed on the fluid hub (10).

13. The thermal management module (100) according to any one of the preceding claims further includes mounting bolts (50) adapted to pass sequentially through aligned mounting holes (32a, 11b, 22a) formed on the fluid pump (30a, 30b), the fluid hub (10) and the heat exchanger, respectively.

14. The thermal management module (100) according to any one of the preceding claims further includes a bracket (80) fixed to the heat exchanger (20) for mounting the heat exchanger (20) on the vehicle frame.

15. The thermal management module (100) according to the preceding claim, wherein, The bracket (80) is formed with a mounting hole (82) that receives a mounting bolt (84) for mounting the bracket (80) on the frame. A damper (82a) is disposed between the mounting hole (82) and the mounting bolt (84) to prevent vibrations from the frame from reaching the heat exchanger (20) and the fluid pumps (30a, 30b) mounted on the heat exchanger (20).

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