An integrated thermal management module and its manufacturing and assembly method

Abstract

This invention discloses an integrated thermal management module and its manufacturing and assembly method. The integrated thermal management module includes a flow channel plate, which includes at least three sub-plates, a middle plate, and a second sub-plate arranged along the thickness direction of the flow channel plate and fixed together by welding. A valve assembly and a pump assembly are respectively provided on the first and second sub-plates. A first plate flow channel communicating with the coolant flow channel of the valve assembly is fixedly connected between the first sub-plate and the middle plate. A second plate flow channel communicating with the coolant flow channel of the pump assembly is fixedly connected between the second sub-plate and the middle plate. A connecting flow channel communicating with the coolant flow channel of the pump assembly is opened in the middle plate. The pump assembly can pressurize and pump the coolant into the valve assembly through the second plate flow channel, the connecting flow channel, and the first plate flow channel. After the valve assembly switches the flow channels, the coolant is distributed to the coolant flow channels of each temperature control circuit.

Description

Technical Field

[0001] This invention relates to the field of thermal management technology for new energy vehicles, specifically to an integrated thermal management module and its manufacturing and assembly method. Background Technology

[0002] The thermal management system for new energy vehicles needs to achieve precise temperature control of the power battery, drive motor, motor controller, and passenger compartment, making it a core system for ensuring vehicle operation safety and ride comfort. Traditional thermal management systems for new energy vehicles use multiple independent functional components such as water pumps, multi-way valves, and heat exchangers, connected by rubber hoses and clamps. This approach has inherent problems such as a large number of parts, large space occupation, complex assembly processes, and a high risk of leakage due to numerous pipe connection points.

[0003] To address the aforementioned shortcomings of traditional thermal management systems, those skilled in the art have begun exploring integrated solutions that integrate multiple functional components into a flow channel plate. Currently, existing integration solutions mainly focus on the integrated design of a single component and the flow channel plate. Representative technologies include: a patent (publication number: CN223024778U) filed by BYD Co., Ltd. in April 2024 and authorized in June 2025, which discloses a structure that integrates the water pump volute and the flow channel plate body, achieving integration of the water pump volute and the flow channel plate and reducing the connecting pipelines between the water pump and the flow channel plate; and a patent (publication number: CN223972411U) filed by Huayu SanDian Automotive Air Conditioning Co., Ltd. in April 2025 and authorized in March 2026, which uses an integral injection molding process to integrate the water valve body and the flow channel plate body, improving the connection and sealing performance between the water valve body and the flow channel plate body.

[0004] However, through practical application and technical analysis, the existing flow channel plate integration solution still has many key technical defects and fails to fundamentally solve the problems of traditional systems, specifically in the following four aspects:

[0005] 1. Insufficient integration: Existing technologies only integrate single-function components such as the volute or valve seat with the flow channel plate, failing to integrate both core functional components simultaneously onto the same flow channel plate. When both the valve seat and volute need to be integrated in practical applications, external piping is still required to connect the two integrated components, failing to fully leverage the integration advantages of the flow channel plate. This results in a still relatively large overall module size, a high number of external interfaces, and the leakage risk is not fundamentally reduced.

[0006] 2. Significant limitations of one-piece injection molding: Attempting to integrate the valve seat and volute on the runner plate using one-piece injection molding presents several technical challenges: First, mold demolding is difficult. The valve seat structure typically features undercuts or deep cavities, while the volute structure is a spirally expanding shape. The coexistence of these two complex structures makes mold demolding difficult, requiring the addition of multiple sliders and cylinders, resulting in an extremely complex mold structure and significantly increased mold costs. Second, wall thickness differences cause molding defects. The valve seat area typically has a wall thickness of 4-6 mm, while the volute area exhibits a gradual thickness change of 2-4 mm. During one-piece injection molding, the cooling rates of different wall thickness areas are inconsistent, easily leading to defects such as shrinkage cavities and warping. Experimental data shows that the product yield under this process is only about 65%. Third, runner layout is limited. The one-piece injection molding process is strictly limited by the demolding direction, making it impossible to achieve complex three-dimensional runner cross-layouts, thus restricting the miniaturization design and runner optimization of the thermal management module.

[0007] 3. Insufficient sealing performance and reliability of split-connection methods: To address the shortcomings of one-piece injection molding, some technical solutions attempt to integrate the valve seat and volute by adhesive bonding after split injection molding. However, the operating environment of the vehicle thermal management system is a cycle of -40℃ to 105℃, under which adhesives are prone to aging, embrittlement, and even detachment, leading to leaks at the component connections. Experiments have verified that adhesive-bonded structures leak even at 0.2MPa pressure, failing to meet the thermal management system's pressure resistance requirement of ≥0.3MPa.

[0008] 4. Serious thermal interference problem exists: Existing integrated solutions do not consider thermal isolation design between different temperature circuits. High temperature circuits (such as motor waste heat recovery circuits, with operating temperatures reaching 60-70℃) and low temperature circuits (such as battery cooling circuits, with operating temperatures controlled at 15-25℃) are directly adjacent inside the flow channel plate, which easily leads to unnecessary heat exchange, causing a large amount of energy loss and significantly reducing the energy efficiency of the thermal management system.

[0009] In summary, how to overcome the limitations of the integrated injection molding process while ensuring sealing performance and structural reliability, achieve efficient integration of the valve seat and volute on the same flow channel plate, and solve the thermal interference problem between different temperature circuits, has become a key technical challenge that urgently needs to be addressed by those skilled in the art. Summary of the Invention

[0010] The purpose of this invention is to overcome the shortcomings of the aforementioned background technology and provide an integrated thermal management module with high integration, where the valve seat and volute are on the same flow channel plate, and which can solve the problem of thermal interference between different temperature circuits, as well as its manufacturing and assembly method.

[0011] To achieve this objective, the integrated thermal management module designed in this invention includes a flow channel plate. The flow channel plate comprises at least three sub-plates, a middle plate, and a second sub-plate, arranged along the thickness direction of the flow channel plate and fixed together by welding to form an integral structure. A valve assembly and a pump assembly are respectively provided on the first sub-plate and the second sub-plate. A first plate flow channel communicating with the coolant flow channel of the valve assembly is fixedly connected between the first sub-plate and the middle plate. A second plate flow channel communicating with the coolant flow channel of the pump assembly is fixedly connected between the second sub-plate and the middle plate. A connecting flow channel communicating with both the first plate flow channel and the second plate flow channel is opened in the middle plate. The pump assembly can pressurize and pump coolant into the valve assembly through the second plate flow channel, the connecting flow channel, and the first plate flow channel. After the valve assembly switches the flow channels, the coolant is distributed to the coolant flow channels of each temperature control loop.

[0012] Furthermore, a first plate flow channel wall, which is integral with the first sub-plate, is fixedly connected to the surface of the first sub-plate facing the middle plate. A first plate flow channel groove corresponding to the first sub-plate flow channel wall is opened on the surface of the middle plate facing the first sub-plate. The first plate flow channel wall is fixed in the first plate flow channel groove by welding.

[0013] Furthermore, a second plate flow channel wall, which is integral with the second sub-plate, is fixedly connected to the surface of the second sub-plate facing the middle plate. A second plate flow channel groove corresponding to the second sub-plate flow channel wall is opened on the surface of the middle plate facing the second sub-plate. The second plate flow channel wall is fixed in the second plate flow channel groove by welding.

[0014] Furthermore, the valve body assembly includes a valve seat fixedly connected to the surface of the first sub-plate facing away from the middle plate. The valve seat has a valve cavity for accommodating the valve core and sealingly engaging with the outer surface of the valve core. The valve core is sealed and fitted within the valve seat. A valve core drive is fixed to the surface of the first sub-plate facing away from the middle plate, and the output shaft of the valve core drive is connected to the valve core.

[0015] Furthermore, the valve seat has multiple valve ports that communicate with the flow channels of the first plate.

[0016] Furthermore, the pump body assembly includes a volute fixedly connected to the surface of the second sub-plate facing away from the middle plate. The volute has an impeller cavity for accommodating an impeller, and the impeller is installed in the impeller cavity. An impeller drive motor is fixed to the surface of the second sub-plate facing away from the middle plate. The motor shaft of the impeller drive motor is connected to the impeller. A spirally expanding volute flow channel is provided around the impeller inside the volute.

[0017] Furthermore, the volute flow channel includes a volute flow channel outlet that communicates with the second subplate flow channel.

[0018] Furthermore, a heat insulation cavity is provided between the first sub-plate and the middle plate, and between the middle plate and the second sub-plate. The heat insulation cavity is located between the high-temperature coolant flow channel circuit and the low-temperature coolant flow channel circuit.

[0019] Furthermore, the manufacturing and assembly method of the integrated thermal management module includes: manufacturing the first sub-plate, the middle plate, and the second sub-plate separately by injection molding; installing the valve body assembly and the pump body assembly; and welding and fixing the first sub-plate, the middle plate, and the second sub-plate into an integral structure along the thickness direction of the flow channel plate.

[0020] Furthermore, the method for manufacturing the first sub-plate, the middle plate, and the second sub-plate by injection molding and split manufacturing includes: injection molding the flow channel wall of the first plate flow channel to the first sub-plate into an integral structure; injection molding the flow channel wall of the second plate flow channel to the second sub-plate into an integral structure; injection molding a first plate flow channel groove that mates with the flow channel wall of the first plate flow channel on the side surface of the middle plate facing the first sub-plate; and injection molding a second plate flow channel groove that mates with the flow channel wall of the second plate flow channel on the side surface of the middle plate facing the second sub-plate.

[0021] The method for welding and fixing the first sub-plate, the middle plate, and the second sub-plate into an integral structure along the thickness direction of the flow channel plate includes: inserting and welding the flow channel wall of the first plate and the flow channel wall of the second plate into the flow channel groove of the first plate and the flow channel groove of the second plate, respectively.

[0022] The beneficial effects of this invention are as follows: The integrated thermal management module and its manufacturing and assembly method proposed in this invention, through the integrated design of split injection molding and welding, break through the technical bottleneck of existing water-side thermal management systems for new energy vehicles. It also solves industry pain points such as insufficient integration, process limitations, poor sealing reliability, and thermal interference. Compared with traditional thermal management systems and existing integrated solutions, it has significant advantages in structural design, process implementation, performance, and cost control, as detailed below:

[0023] Significantly improving integration and reducing leakage risk at its source: This invention integrates the valve body assembly and pump body assembly onto the first and second sub-plates of the flow channel plate, respectively. Internal communication between the two flow channels is achieved through a connecting channel within the middle plate. This is the first time that the two core components, the valve seat and the volute, have been efficiently integrated on the same flow channel plate, eliminating the need for external piping connections. Compared to existing single-component integration solutions, this reduces 2-3 external connection interfaces, shrinks the overall module size by 35% compared to traditional independent component solutions, reduces the number of parts by approximately 40%, significantly reduces piping connection points, fundamentally lowers the risk of coolant leakage, and improves the module's structural compactness.

[0024] Overcoming the limitations of one-piece injection molding, improving product yield and reducing mold costs: This invention uses a split injection molding process to manufacture the first sub-plate, the middle plate, and the second sub-plate. The valve seat, the volute, and the matching flow channel walls of the first and second plates are injection molded integrally with their respective sub-plates. The mold structure of each sub-plate is simple, avoiding the mold demolding difficulties caused by the coexistence of the valve seat undercut / deep cavity structure and the spiral gradually expanding structure of the volute during one-piece injection molding. No additional sliders and cylinders are required. At the same time, the injection molding process parameters can be optimized separately according to the structural characteristics of each sub-plate (such as the thick wall of the valve seat and the gradually changing wall thickness of the volute). This completely solves the molding defects such as shrinkage cavities and warping caused by uneven cooling in areas with different wall thicknesses. The product yield is increased from 65% of the existing one-piece injection molding to over 95%, and the mold manufacturing cost is reduced by about 40% compared to the one-piece injection molding solution.

[0025] Employing a welded sealing connection ensures high sealing performance and long-term reliability: This invention abandons adhesive bonding, welding and fixing the flow channel walls of the first and second plates respectively into the flow channel grooves of the first and second plates of the middle plate. The first sub-plate, middle plate, and second sub-plate are integrally welded into a single structure, achieving molecular-level fusion at the weld joint, with a weld strength exceeding 90% of the base material strength. Testing shows that the burst pressure of the welded flow channel plate can reach 1.2 MPa, far exceeding the industry's pressure resistance requirement of ≥0.6 MPa, and its airtightness is <0.5 cc / min, better than the industry standard of ≤1.0 cc / min. Furthermore, the welded structure can withstand thermal cycling tests from -40℃ to 105℃ (more than 500 cycles) without leakage or deformation. In the complex operating environment of vehicle thermal management systems, its sealing performance and structural reliability are far superior to adhesive bonding solutions.

[0026] Achieving flexible three-dimensional flow channel layout, reducing flow resistance and improving system efficiency: This invention utilizes a split structural design, employing a connecting flow channel in the middle plate to link the flow channels of the first and second plates. Combined with the welded flow channel walls and grooves between the sub-plates, this overcomes the limitations of one-piece injection molding on the demolding direction, enabling complex three-dimensional intersecting flow channel layouts. Simultaneously, the spiral-expanding volute flow channel within the volute housing seamlessly connects with the flow channel of the second plate, resulting in a smoother coolant flow path, effectively optimizing flow resistance distribution, reducing pressure loss, and improving coolant circulation efficiency, thereby enhancing the overall efficiency of the thermal management system.

[0027] Integrated heat insulation cavity structure reduces thermal interference and energy loss: This invention incorporates heat insulation cavities between the first sub-plate and the middle plate, and between the middle plate and the second sub-plate. These cavities are precisely positioned between the high-temperature coolant flow path (e.g., the motor waste heat recovery circuit) and the low-temperature coolant flow path (e.g., the battery cooling circuit). This heat insulation cavity is a sealed air layer, effectively blocking heat transfer between different temperature circuits by utilizing the low thermal conductivity of air. Without requiring additional components or processing steps, it reduces system energy loss by approximately 5%–8%, significantly improving the energy efficiency of the thermal management system. Simultaneously, it ensures that core components such as the battery and motor operate within their optimal temperature ranges, extending component lifespan.

[0028] By selecting high-polymer materials and optimizing the process, the overall cost is significantly reduced: The flow channel plate and integrated valve seat, volute and other structures of this invention are all made of high-polymer materials such as glass fiber reinforced polyamide or polyphenylene sulfide. These materials have a heat distortion temperature ≥150℃ and a tensile strength ≥100MPa, which meets the high temperature and high pressure requirements of the thermal management system. Moreover, the material cost is reduced by about 60% compared with the traditional metal die casting solution. At the same time, the split injection molding + welding process simplifies the production process, and the integrated design reduces the procurement of parts and assembly processes, significantly reducing the cost of manual assembly. The overall cost is reduced by about 30%-40% compared with the traditional thermal management system solution, which has significant economic benefits.

[0029] Standardized structural design enhances assembly convenience and versatility: The outer surface of the flow channel plate of this invention can be integrally formed with multiple standardized interfaces, and the opening end faces of the interfaces can be designed to be on the same plane, which facilitates quick insertion with external temperature control components or pipelines such as radiators, battery packs, and heater cores during vehicle assembly, greatly improving assembly efficiency and reducing assembly difficulty; at the same time, the split manufacturing and assembly method adapts to the thermal management requirements of different vehicle models, and modular adaptation can be achieved by adjusting the flow channel layout and interface specifications, improving the versatility and adaptability of the product.

[0030] The manufacturing and assembly process is simple and suitable for large-scale industrial production: The manufacturing and assembly method of this invention adopts a three-step core process of split injection molding, component pre-assembly, and overall welding. Each process is mature and easy to operate. Both injection molding and welding can be automated without complicated manual debugging. Moreover, the injection molding of each sub-plate, the pre-assembly of valve body components and pump body components can be carried out simultaneously, which greatly shortens the production cycle, improves production efficiency, and is fully adapted to the needs of large-scale industrial production, with strong industrial applicability.

[0031] In summary, the integrated thermal management module and its manufacturing and assembly method designed in this invention overcome the technical bias of those skilled in the art regarding the reliability of separate connections through dual innovation in structure and process. It achieves efficient integration of the valve seat and the volute, while solving multiple technical problems such as sealing, thermal interference, and process limitations. While improving the performance and reliability of the thermal management system, it also achieves lightweighting, miniaturization, and low cost. It can be widely used in various new energy vehicles such as pure electric vehicles, hybrid electric vehicles, and fuel cell vehicles, and can also be extended to fields such as thermal management of energy storage equipment and liquid cooling systems for data centers, with broad application prospects. Attached Figure Description

[0032] To more clearly illustrate the technical solutions of the embodiments disclosed in this invention, the accompanying drawings of the embodiments will be briefly described below. These drawings are for illustrative purposes only and are not intended to limit the scope of protection of this invention.

[0033] Figure 1 This is a front axonometric view of the integrated thermal management module designed in this invention.

[0034] Figure 2 Rear-view isometric view of the integrated thermal management module designed in this invention;

[0035] Figure 3 This is a front axonometric view of the first plate flow channel welded and fixed to the middle plate in this invention;

[0036] Figure 4 This is a front axonometric view of the integrated thermal management module in this invention without the valve core and valve core drive component installed.

[0037] Figure 5 Explosion of the integrated thermal management module designed for this invention Figure 1 ;

[0038] Figure 6 Explosion of the integrated thermal management module designed for this invention Figure 2 ;

[0039] Figure 7 This is a front axonometric view of the second plate flow channel welded and fixed to the middle plate in this invention;

[0040] Figure 8 This is a front view of the flow channel groove of the first plate in this invention;

[0041] Figure 9 This is a front view of the flow channel groove of the second plate in this invention;

[0042] Wherein, 1—flow channel plate (1.1—first sub-plate, 1.2—middle plate, 1.3—second sub-plate), 2—valve body assembly (2.1—valve seat, 2.2—valve core and valve core drive component), 3—pump body assembly (3.1—volute, 3.2—impeller and impeller drive motor), 4—first plate flow channel, 5—second plate flow channel, 6—first plate flow channel wall, 7—first plate flow channel groove, 8—second plate flow channel wall, 9—second plate flow channel groove, 10—valve port, 11—volute flow channel outlet, 12—connecting flow channel. Detailed Implementation

[0043] The technical solutions (including preferred technical solutions) of the present invention will be further described in detail below with reference to the accompanying drawings and by listing some optional embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. In the description of the present invention, it should be understood that the terms "upper," "lower," "front," "rear," "left," "right," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the present invention.

[0044] Example 1

[0045] This embodiment discloses an integrated thermal management module applied to the water-side thermal management system of a pure electric passenger vehicle. It can achieve precise distribution and circulation control of coolant in four temperature control circuits: power battery, drive motor, motor controller, and passenger compartment heating. The module has a compact overall structure, excellent sealing performance, and no thermal interference issues.

[0046] The integrated thermal management module includes a flow channel plate 1, and valve body assembly 2 and pump body assembly 3 respectively assembled on both sides of the flow channel plate 1. The flow channel plate 1 consists of three sub-plates: a first sub-plate 1.1, a middle plate 1.2, and a second sub-plate 1.3, which are stacked along the thickness direction and fixed into an integral structure by hot gas welding. All three sub-plates are made of 30% glass fiber reinforced PA66 polymer material, with a heat distortion temperature ≥250℃ and a tensile strength ≥180MPa, meeting the requirements of cold and hot cycle working environment from -40℃ to 105℃.

[0047] The valve body assembly 2 is assembled on the side surface of the first sub-plate 1.1 facing away from the middle plate 1.2, and includes a valve seat 2.1, a valve core, and a valve core drive component 2.2. The valve seat 2.1 is integrally injection molded with the first sub-plate 1.1. A cylindrical valve cavity is opened inside the valve seat 2.1. The inner wall of the valve cavity is precision machined to form a sealing surface. The valve core is made of ceramic material and is installed in the valve cavity in a sealing fit. The valve core drive component is a stepper motor, which is fixed to the surface of the first sub-plate 1.1 by bolts. Its output shaft is connected to the valve core drive. The flow channel can be opened and closed and switched by controlling the rotation angle of the valve core. The valve seat 2.1 has multiple valve ports 10, all of which are connected to the first plate flow channel 4 between the first sub-plate 1.1 and the middle plate 1.2. The first sub-plate 1.1 has an integrally injection-molded first plate flow channel wall 6 on the side surface facing the middle plate 1.2. The flow channel wall has an arc-shaped protrusion structure that is adapted to the first plate flow channel groove 7 on the middle plate 1.2. After the first plate flow channel wall 6 is inserted into the first plate flow channel groove 7, it is welded by hot gas welding. The two are joined together to form a sealed first plate flow channel 4, realizing the flow channel communication between the valve body assembly 2 and the middle plate 1.2.

[0048] The pump body assembly 3 is assembled on the side surface of the second sub-plate 1.3 facing away from the middle plate 1.2, including the volute 3.1, impeller and impeller drive motor 3.2; the volute 3.1 is integrally injection molded with the second sub-plate 1.3, and an impeller cavity is opened inside the volute 3.1. The centrifugal plastic impeller is installed in the impeller cavity with clearance fit. The impeller drive motor is a brushless DC motor, which is double fixed to the surface of the second sub-plate 1.3 by clips and bolts. Its motor shaft extends into the impeller cavity and is connected to the impeller drive, driving the impeller to rotate at high speed to realize the pressurization of coolant. A spirally expanding volute flow channel is arranged around the impeller cavity inside the volute 3.1. The end of the volute flow channel is the volute flow channel outlet 11, which is seamlessly connected to the second plate flow channel 5 between the second sub-plate 1.3 and the middle plate 1.2. On the side surface of the second sub-plate 1.3 facing the middle plate 1.2, a second plate flow channel wall 8 is integrally injection molded with the second sub-plate 1.3. This flow channel wall is an arc-shaped protrusion structure of the same specification as the first plate flow channel wall 6, which is adapted to the second plate flow channel groove 9 on the middle plate 1.2. After the second plate flow channel wall 8 is inserted into the second plate flow channel groove 9, it is welded by hot gas welding. The two are closed to form the second plate flow channel 5, realizing the flow channel communication between the pump body assembly 3 and the middle plate 1.2.

[0049] The middle plate 1.2 is the core connecting component of the flow channel plate 1. It has a connecting flow channel 12 inside, which is a three-dimensional cross flow channel. It is connected to the first plate flow channel 4 and the second plate flow channel 5, realizing the internal flow channel connection between the pump body assembly 3 and the valve body assembly 2. The coolant can enter the valve body assembly 2 through the second plate flow channel 5, the connecting flow channel 12, and the first plate flow channel 4 without the need for external pipeline connection. Hollow heat insulation cavities are reserved between the first sub-plate 1.1 and the middle plate 1.2, and between the middle plate 1.2 and the second sub-plate 1.3. The heat insulation cavity is a sealed air layer with a thickness of 3mm. It extends along the flow channel and is precisely arranged between the high temperature circuit (motor / controller cooling circuit, 60-70℃) and the low temperature circuit (battery cooling circuit, 15-25℃). It effectively blocks heat transfer by utilizing the low thermal conductivity of air (0.026W / m・K) to avoid thermal interference between circuits of different temperatures.

[0050] The working method of the above-mentioned integrated thermal management module is as follows: the impeller drive motor drives the impeller to rotate, drawing the coolant into the impeller cavity of the volute 3.1. After the coolant is stabilized and pressurized by the spiral gradually expanding volute flow channel, it enters the second plate flow channel 5 from the volute flow channel outlet 11. The coolant flows into the connecting flow channel 12 of the middle plate 1.2 through the second plate flow channel 5, and then enters the first plate flow channel 4 through the connecting flow channel 12. The coolant enters the valve cavity of the valve seat 2.1 from the valve port 10 through the first plate flow channel 4. The valve core drive component 2.2 controls the rotation of the valve core, realizing the precise distribution of coolant in the four temperature control circuits of the power battery, drive motor, motor controller, and passenger compartment heating. Finally, it is delivered to each temperature control component through the standardized interface on the outer surface of the flow channel plate 1.

[0051] Example 2

[0052] This embodiment discloses the manufacturing and assembly method of the integrated thermal management module in Embodiment 1. It adopts the core process of split injection molding → component pre-assembly → hot gas welding → overall assembly. Each process is mature and can be automated, making it suitable for large-scale industrial production. The specific steps are as follows:

[0053] Step S1: Separate injection molding of each sub-plate of the runner plate

[0054] A horizontal injection molding machine was used, with 30% glass fiber reinforced PA66 as raw material, to injection mold the first sub-plate 1.1, the middle plate 1.2, and the second sub-plate 1.3 respectively. The injection molding process parameters were uniformly set as follows: injection temperature 280±5℃, injection pressure 80±5MPa, holding pressure 60±5MPa, holding time 10s, and cooling time 30s.

[0055] When injection molding the first sub-plate 1.1, the valve seat 2.1, the flow channel wall 6 of the first plate, and the first sub-plate 1.1 are integrally injection molded together, and the inner wall of the valve cavity of the valve seat 2.1 is reserved for machining allowance;

[0056] When injection molding the middle plate 1.2, the first plate flow channel groove 7 is integrally injection molded on the side surface facing the first sub-plate 1.1, and the second plate flow channel groove 9 is integrally injection molded on the side surface facing the second sub-plate 1.3. At the same time, the connecting flow channel 12 is injection molded inside the middle plate 1.2.

[0057] When injection molding the second sub-plate 1.3, the volute 3.1, the flow channel wall 8 of the second plate, and the second sub-plate 1.3 are integrally injection molded. The inner wall of the impeller cavity of the volute 3.1 is smoothed.

[0058] After injection molding, each sub-plate is deburred and chamfered, and the inner wall of the valve cavity of valve seat 2.1 is precision machined to ensure that the surface roughness of the sealing surface meets the set requirements. After completion, appearance and size inspection are carried out, and unqualified products are rejected.

[0059] Step S2: Pre-assembly of valve body assembly 2 and pump body assembly 3

[0060] Valve body assembly 2 pre-installation: The ceramic valve core is sealed and installed in the valve seat 2.1 valve cavity of the first sub-plate 1.1. The valve core is manually rotated to test its rotation flexibility and ensure that there is no jamming. The valve core drive component 2.2 (stepper motor) is fixed to the surface of the first sub-plate 1.1 with bolts. The motor output shaft is precisely connected to the valve core to complete the transmission connection. The rotation angle accuracy of the valve core is tested by powering on to ensure accurate flow channel switching.

[0061] Pre-installation of pump body assembly 3: Install the centrifugal impeller with clearance fit into the impeller cavity of the volute 3.1 of the second sub-plate 1.3, and manually rotate the impeller to check its smooth operation; fix the impeller drive motor 3.2 (brushless DC motor) to the surface of the second sub-plate 1.3 with clips and bolts, insert the motor shaft into the impeller cavity and connect it with the impeller to complete the transmission connection, and test the rotation speed of the impeller to ensure that the coolant pressurization effect meets the standard.

[0062] Step S3: Hot gas welding of each sub-plate

[0063] A fully automatic hot gas welding machine was used to perform layer welding on the first sub-plate 1.1, the middle plate 1.2, and the second sub-plate 1.3. The welding depth was controlled to be 1 / 3 to 1 / 2 of the sub-plate wall thickness (1.5 mm in this embodiment) to ensure that a molecular-level fusion structure was formed at the weld. The specific operation is as follows:

[0064] Welding of the first sub-plate 1.1 and the middle plate 1.2: The first plate flow channel wall 6 of the first sub-plate 1.1 is precisely inserted into the first plate flow channel groove 7 of the middle plate 1.2, and the two are precisely positioned by the welding machine positioning mechanism; the welding interface is preheated to 200±10℃ using a hot air gun, and then the welding temperature is increased to 320±10℃, a welding pressure of 0.2±0.02MPa is applied, and the welding time is 15±2s; after welding, the pressure is held and cooled for 30s to allow the welding interface to fully solidify.

[0065] Welding of the second sub-plate 1.3 and the middle plate 1.2: The second plate flow channel wall 8 of the second sub-plate 1.3 is precisely inserted into the second plate flow channel groove 9 of the middle plate 1.2, and the same hot gas welding process parameters as above are used for preheating, welding, pressure holding and cooling; during the welding process, the overflow groove on the outer periphery of the welding interface is used to contain the extruded molten material to avoid overflow flowing into the flow channel and causing blockage.

[0066] Welding quality inspection: After welding is completed, visually inspect whether there is uniform overflow in the overflow trough. Use an air tightness tester to test the air tightness of the first plate flow channel 4, the second plate flow channel 5, and the connecting flow channel 12. The air tightness is required to be <0.5cc / min. At the same time, a pressure resistance test is performed, and the burst pressure is required to be ≥1.2MPa. Products that fail the test are reworked or rejected.

[0067] Step S4: Overall module assembly and performance testing

[0068] Standardized interface assembly: Sealing grooves are opened at each standardized interface on the outer surface of the flow channel plate 1, and high and low temperature resistant fluororubber O-rings are embedded to ensure a sealed fit with external pipelines.

[0069] Overall performance testing: The assembled integrated thermal management module is connected to the test bench to simulate the actual working environment of the vehicle and conduct coolant circulation test, flow channel switching test, hot and cold cycle test (-40℃~105℃, 500 times), and long-term reliability test. During the test, it is ensured that the coolant distribution of the four temperature control circuits is accurate, there is no leakage in the flow channel, there is no obvious thermal interference in different temperature circuits, and all performance indicators meet the standards.

[0070] Finished product packaging: Products that pass performance tests are cleaned and dried, and then packaged with anti-static foam before being put into storage.

[0071] Each process in this manufacturing and assembly method can be automated and carried out on an assembly line. The injection molding of the first sub-plate 1.1 and the second sub-plate 1.3 and the pre-assembly of components can be carried out simultaneously, which greatly shortens the production cycle. Furthermore, the welding process replaces the traditional adhesive bonding, which improves the sealing performance and structural reliability of the module. The yield rate of finished products can reach more than 95%, and the overall production efficiency is more than 50% higher than that of the traditional process.

[0072] In summary, the integrated thermal management module and its manufacturing and assembly method designed in this invention overcome the technical bias of those skilled in the art regarding the reliability of separate connections through dual innovation in structure and process. It achieves efficient integration of the valve seat and the volute, while solving multiple technical problems such as sealing, thermal interference, and process limitations. While improving the performance and reliability of the thermal management system, it also achieves lightweighting, miniaturization, and low cost. It can be widely used in various new energy vehicles such as pure electric vehicles, hybrid electric vehicles, and fuel cell vehicles, and can also be extended to fields such as thermal management of energy storage equipment and liquid cooling systems for data centers, with broad application prospects.

[0073] It should be noted that the above description of the technical solutions is exemplary, and this specification may be embodied in different forms and should not be construed as limiting it to the technical solutions set forth herein. Rather, providing these descriptions will make the disclosure of this invention thorough and complete, and will fully convey the scope of this specification to those skilled in the art. Furthermore, the technical solutions of this invention are defined only by the scope of the claims.

[0074] The shapes, dimensions, ratios, angles, and figures disclosed in the description of various aspects of this specification and claims are merely examples, and therefore, this specification and claims are not limited to the details shown. In the following description, detailed descriptions of relevant known functions or configurations will be omitted where it would be determined that they unnecessarily obscure the focus of this specification and claims.

[0075] When using the terms “comprising,” “having,” and “including” as described in this specification, there may also be another part or other parts, and the terms used may generally be singular or plural.

[0076] It should be noted that although the terms "first," "second," "top," "bottom," "one side," "the other side," "one end," "the other end," etc., may appear and be used in this specification to describe various different components, these components and parts should not be limited by these terms. These terms are only used to distinguish one component from another. For example, without departing from the scope of this specification, a first component may be referred to as a second component, and similarly, a second component may be referred to as a first component; top and bottom components may, under certain circumstances, be interchanged or converted; components at one end and at the other end may have the same or different performance characteristics.

[0077] Finally, it should be noted that the above embodiments are merely representative examples of the present invention. Obviously, the present invention is not limited to the above embodiments and many variations are possible. Any simple modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention should be considered within the protection scope of the present invention.

Claims

1. An integrated thermal management module, characterized in that: It includes a flow channel plate (1), which comprises at least three parts arranged along the thickness direction of the flow channel plate and fixed together by welding to form an integral structure: a first sub-plate (1.1), a middle plate (1.2), and a second sub-plate (1.3). A valve body assembly (2) and a pump body assembly (3) are respectively provided on the first sub-plate (1.1) and the second sub-plate (1.3). A first plate flow channel (4) communicating with the coolant flow channel of the valve body assembly (2) is fixedly connected between the first sub-plate (1.1) and the middle plate (1.2). The second sub-plate (1.3) A second plate flow channel (5) is fixedly connected to the middle plate (1.2) and communicates with the coolant flow channel of the pump assembly (3). The middle plate (1.2) has a connecting flow channel (12) that communicates with both the first plate flow channel (4) and the second plate flow channel (5). The pump assembly (3) can pressurize and pump the coolant into the valve assembly (2) through the second plate flow channel (5), the connecting flow channel (12) and the first plate flow channel (4). After the flow channel is switched by the valve assembly (2), the coolant is distributed to the coolant flow channels of each temperature control circuit.

2. The integrated thermal management module as described in claim 1, characterized in that: The surface of the first sub-plate (1.1) facing the middle plate (1.2) is fixedly connected with a first plate flow channel wall (6) that is integral with the first sub-plate (1.1). The surface of the middle plate (1.2) facing the first sub-plate (1.1) is provided with a first plate flow channel groove (7) corresponding to the first sub-plate flow channel wall (6). The first plate flow channel wall (6) is fixed in the first plate flow channel groove (7) by welding.

3. The integrated thermal management module as described in claim 1, characterized in that: The surface of the second sub-plate (1.3) facing the middle plate (1.2) is fixedly connected with a second plate flow channel wall (8) that is integral with the second sub-plate (1.3). The surface of the middle plate (1.2) facing the second sub-plate (1.3) is provided with a second plate flow channel groove (9) corresponding to the second sub-plate flow channel wall (8). The second plate flow channel wall (8) is fixed in the second plate flow channel groove (9) by welding.

4. The integrated thermal management module as described in claim 1, characterized in that: The valve body assembly (2) includes a valve seat (2.1) fixedly connected to the surface of the first sub-plate (1.1) facing away from the middle plate (1.2). The valve seat (2.1) is provided with a valve cavity for accommodating the valve core and sealingly engaging with the outer surface of the valve core. The valve core is sealed and fitted inside the valve seat (2.1). A valve core drive is fixed to the surface of the first sub-plate (1.1) facing away from the middle plate (1.2). The output shaft of the valve core drive is connected to the valve core.

5. The integrated thermal management module as described in claim 4, characterized in that: The valve seat (2.1) has multiple valve ports (10) that communicate with the flow channel (4) of the first plate.

6. The integrated thermal management module as described in claim 1, characterized in that: The pump body assembly (3) includes a volute (3.1) fixedly connected to the surface of the second sub-plate (1.3) facing away from the middle plate (1.2). The volute (3.1) has an impeller cavity for accommodating the impeller, and the impeller is installed in the impeller cavity. An impeller drive motor is fixed to the surface of the second sub-plate (1.3) facing away from the middle plate (1.2). The motor shaft of the impeller drive motor is connected to the impeller. A spirally expanding volute flow channel is provided around the impeller in the volute (3.1).

7. The integrated thermal management module as described in claim 6, characterized in that: The volute flow channel includes a volute flow channel outlet (11) that communicates with the second sub-plate flow channel (5).

8. The integrated thermal management module as described in claim 1, characterized in that: A heat insulation cavity is provided between the first sub-plate (1.1) and the middle plate (1.2), and between the middle plate (1.2) and the second sub-plate (1.3). The heat insulation cavity is located between the high-temperature coolant flow channel circuit and the low-temperature coolant flow channel circuit.

9. A method for manufacturing and assembling an integrated thermal management module according to any one of claims 1-8, characterized in that: It includes: The first sub-plate (1.1), the middle plate (1.2), and the second sub-plate (1.3) are manufactured by injection molding and in a split manner; the valve body assembly (2) and the pump body assembly (3) are installed; the first sub-plate (1.1), the middle plate (1.2), and the second sub-plate (1.3) are welded and fixed into an integral structure along the thickness direction of the flow channel plate (1).

10. The manufacturing and assembly method of the integrated thermal management module as described in claim 9, characterized in that: The method of manufacturing the first sub-plate (1.1), the middle plate (1.2), and the second sub-plate (1.3) by injection molding and split manufacturing includes: injection molding the flow channel wall of the first plate flow channel (4) with the first sub-plate (1.1) into an integral structure; injection molding the flow channel wall of the second plate flow channel (5) with the second sub-plate (1.3) into an integral structure; injection molding a first plate flow channel groove (7) that cooperates with the flow channel wall of the first plate flow channel (4) on the side surface of the middle plate (1.2) facing the first sub-plate (1.1); and injection molding a second plate flow channel groove (8) that cooperates with the flow channel wall of the second plate flow channel (5) on the side surface of the middle plate (1.2) facing the second sub-plate (1.3). The method of welding and fixing the first sub-plate (1.1), the middle plate (1.2) and the second sub-plate (1.3) into an integral structure along the thickness direction of the flow channel plate (1) includes: inserting and welding the flow channel wall of the first plate flow channel (4) and the flow channel wall of the second plate flow channel (5) into the first plate flow channel groove (7) and the second plate flow channel groove (8) respectively.

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