Thermal management assembly, thermal management system and motor vehicle

Abstract

The utility model provides a thermal management system. The thermal management system is provided with a refrigerant loop and a control unit (6). A gas-liquid separator (5) is arranged in the refrigerant circuit. The overall temperature of the control unit (6) is higher than the overall temperature of the gas-liquid separator (5). The gas-liquid separator (5) and the control unit (6) form an integrated heat management assembly, so that the gas-liquid separator (5) is allowed to serve as a cold source to cool the control unit (6). The utility model further provides a motor vehicle. The motor vehicle comprises the thermal management system.

Description

Technical Field

[0001] This utility model relates to a thermal management component, a thermal management system including the thermal management component, and a motor vehicle using the thermal management system. Background Technology

[0002] As the thermal management systems of motor vehicles develop towards integration, water plates and refrigerant plates are often used to replace some of the piping in the thermal management system. Thermal management components such as water pumps, electronic expansion valves, and fluid switching valves are integrated into the water plates and refrigerant plates, thus forming a fluid management device to simplify system layout and facilitate maintenance.

[0003] Figure 1A This is an architecture diagram of a thermal management system for motor vehicles in the prior art. (Reference) Figure 1A The thermal management system includes a coolant circuit (not shown), a refrigerant circuit, and a control unit 6. Along the refrigerant flow direction ( Figure 1A (As indicated by the black arrow in the diagram), the refrigerant circuit sequentially includes compressor 1, water-cooled condenser 2, electronic expansion valve 3, evaporator 4, and gas-liquid separator 5. When the thermal management system is working, the high-temperature, high-pressure refrigerant discharged from compressor 1 flows through water-cooled condenser 2 and, after condensation, flows to electronic expansion valve 3. After being throttled by electronic expansion valve 3, it becomes low-temperature, low-pressure refrigerant. The low-temperature, low-pressure refrigerant flows to evaporator 4 to evaporate and absorb heat from the outside. The low-temperature, low-pressure refrigerant flowing out of the outlet of evaporator 4 includes gaseous and liquid refrigerant. This refrigerant flows through gas-liquid separator 5 to achieve gas-liquid separation. Among them, gaseous refrigerant is discharged and returned to compressor 1 (in the refrigerant circuit, the refrigerant between the outlet of electronic expansion valve 3 and the inlet of compressor 1 is usually called low-pressure refrigerant, and the refrigerant between the outlet of compressor 1 and the inlet of electronic expansion valve 3 is called high-pressure refrigerant). During this period, the control unit 6 can communicate with the compressor 1, the electronic expansion valve 3, and coolant circuit components (not shown) such as water pumps, water valves, and sensors to control the thermal management system.

[0004] In the prior art, fluid management devices integrate circuit boards from electronic components such as electronic expansion valve 3 and shut-off valve (not shown) into a single circuit board (PCBA), which is then installed in a housing to form a control unit 6. This further improves integration, saves costs, and facilitates control.

[0005] However, in control unit 6, integrating the circuit boards of various independently distributed electronic components into a single circuit board results in the heat-generating devices from these components being concentrated on one board. This leads to excessive heat generation during operation, causing the circuit board to overheat and potentially causing malfunctions. Therefore, it is desirable to cool control unit 6 without significantly increasing the structural complexity and manufacturing cost of the thermal management system. Utility Model Content

[0006] [Technical Objective]

[0007] This utility model was developed to solve the above-mentioned technical problems and other potential technical problems.

[0008] [Technical Solution]

[0009] One aspect of this invention provides a thermal management component, which includes a gas-liquid separator and a control unit. The gas-liquid separator and the control unit are integrated to allow the gas-liquid separator to act as a cold source to cool the control unit.

[0010] Optionally, the gas-liquid separator and the control unit are assemblies or integrally molded parts.

[0011] Preferably, the housing of the gas-liquid separator and the housing of the control unit are both made of thermally conductive material, and the housing of the control unit is tightly fitted to the housing of the gas-liquid separator.

[0012] Optionally, the housing of the control unit is integrally formed with the end cap on the housing of the gas-liquid separator. Optionally, the control unit is assembled to the gas-liquid separator by bolts, adhesives, welding, or snap-fits.

[0013] Optionally, a printed circuit board assembly (PCBA) is provided inside the housing of the control unit.

[0014] Optionally, the gas-liquid separator has a base in which a low-pressure refrigerant inlet and a low-pressure refrigerant outlet are provided.

[0015] Optionally, a high-pressure refrigerant inlet and a high-pressure refrigerant outlet are provided in the end cap. A conduit is provided between the high-pressure refrigerant inlet and the high-pressure refrigerant outlet to allow fluid communication between them, and the wall of the conduit is thermally conductive to allow heat exchange between the high-pressure refrigerant flowing in the conduit and the low-pressure refrigerant in the gas-liquid separator.

[0016] Optionally, the conduit is U-shaped and extends to the bottom of the gas-liquid separator so that the low-pressure refrigerant at the bottom of the gas-liquid separator comes into as much contact as possible with the conduit.

[0017] Optionally, a first riser is provided on the base, the lower end of the first riser is fixed in the base and communicates with the low-pressure refrigerant inlet, and the upper end of the first riser opens toward the end cap. A second riser is provided on the base, the lower end of the second riser is fixed in the base and communicates with the low-pressure refrigerant outlet, and the upper end of the second riser opens toward the end cap.

[0018] Preferably, a baffle is provided in the gas-liquid separator at least between the upper opening of the first riser and the upper opening of the second riser to prevent the refrigerant flowing into the gas-liquid separator through the upper opening of the first riser from flowing directly into the upper opening of the second riser.

[0019] Optionally, a plurality of baffles are provided in the gas-liquid separator, and the baffles are provided with notches to allow refrigerant to pass through.

[0020] Another aspect of this invention provides a thermal management system suitable for motor vehicles, the thermal management system having a refrigerant circuit and a control unit, wherein a gas-liquid separator is arranged in the refrigerant circuit. The thermal management system includes the thermal management components according to the preceding aspect.

[0021] Optionally, along the refrigerant flow direction, the refrigerant circuit sequentially includes a compressor, a condenser, an electronic expansion valve, an evaporator, and the gas-liquid separator. The control unit is communicatively connected to components of the thermal management system to control the thermal management system. These components include a compressor, an electronic expansion valve, and / or sensors.

[0022] Another aspect of this utility model provides a motor vehicle, the motor vehicle including the thermal management system according to the preceding aspect.

[0023] [Technical Effects]

[0024] This invention integrates the control unit with the gas-liquid separator in the thermal management system, enabling the control unit to be cooled by the gas-liquid separator without the need for additional heat exchange / heat dissipation structures (such as fluid heat exchange channels or heat exchange fins). Therefore, it effectively utilizes the cooling capacity of the gas-liquid separator, achieving the goal of energy saving and consumption reduction, without significantly increasing the structural complexity and manufacturing cost of the thermal management system. Attached Figure Description

[0025] To facilitate understanding of this invention, it will be described in more detail below based on exemplary embodiments and in conjunction with the accompanying drawings. The same or similar reference numerals are used in the drawings to denote the same or similar components. It should be understood that the drawings are merely schematic, and the dimensions and proportions of the components in the drawings are not necessarily precise.

[0026] Figure 1A This is an architecture diagram of the thermal management system for motor vehicles in the prior art.

[0027] Figure 1B This is an architectural diagram of a thermal management system according to an exemplary embodiment of the present invention.

[0028] Figure 2A and Figure 2B This is a perspective view of a thermal management component according to an exemplary embodiment of the present invention.

[0029] Figure 2C yes Figure 2A and Figure 2B An exploded perspective view of the thermal management components shown.

[0030] Figure 2D yes Figures 2A to 2C The diagram shows a three-dimensional view of the gas-liquid separator in the thermal management assembly. Figure 2D The casing of the gas-liquid separator was removed for the purpose of conveniently demonstrating its internal structure.

[0031] Figure 2E yes Figures 2A to 2C A longitudinal sectional view of the gas-liquid separator in the thermal management assembly shown.

[0032] Figure 2F yes Figures 2A to 2C The diagram shows a three-dimensional view of the gas-liquid separator in the thermal management assembly. Figure 2F The end cap (top cover) of the gas-liquid separator was removed for the purpose of conveniently demonstrating the internal structure of the gas-liquid separator.

[0033] Figure 3 This is a perspective view of a thermal management component according to another exemplary embodiment of the present invention.

[0034] Figure 4 This is an architecture diagram of a thermal management system according to yet another exemplary embodiment of the present invention. Detailed Implementation

[0035] The "Background Technology" section above has already been referenced. Figure 1A The basic architecture of thermal management systems for motor vehicles in the prior art has been described. Next, reference will be made to... Figure 1B The basic architecture of a thermal management system according to an exemplary embodiment of the present invention is described.

[0036] like Figure 1B As shown, along the direction of refrigerant flow ( Figure 1B (As indicated by the black arrow in the diagram), the refrigerant circuit sequentially includes a compressor 1, a water-cooled condenser 2, an electronic expansion valve 3, an evaporator 4, and a gas-liquid separator 5. A control unit 6 is communicatively connected to the compressor 1, the electronic expansion valve 3, and components such as a water pump, water valve, shut-off valve, and sensors (not shown) to control the thermal management system. In other words, the basic architecture of the thermal management system according to an exemplary embodiment of this utility model is... Figure 1A The basic architectures of the thermal management systems shown are generally similar, with the main difference being the arrangement of the gas-liquid separator 5 and the control unit 6.

[0037] Specifically, the inventors noted that the refrigerant flowing through the gas-liquid separator 5 is low-pressure and low-temperature, while the control unit 6 requires cooling. The overall temperature of the control unit 6 is higher than that of the gas-liquid separator 5. Therefore, the gas-liquid separator 5 can be used as a cold source to cool the control unit 6. The integration method between the control unit 6 and the gas-liquid separator 5 will be described in detail later.

[0038] Figure 2A and Figure 2B This is a perspective view of a thermal management component according to an exemplary embodiment of the present invention. Figure 2C yes Figure 2A and Figure 2B An exploded perspective view of the thermal management components shown. Figure 2D yes Figures 2A to 2C The diagram shows a three-dimensional view of the gas-liquid separator in the thermal management assembly. Figure 2D The casing of the gas-liquid separator was removed for the purpose of conveniently demonstrating its internal structure.

[0039] like Figures 2A to 2C As shown, the thermal management assembly includes a gas-liquid separator 5 and a control unit 6. In this embodiment, the control unit 6 is assembled to the gas-liquid separator 5 by bolts, adhesives, welding, or snap-fits to form an assembly, so that the gas-liquid separator 5 and the control unit 6 are constructed as a single unit, allowing the gas-liquid separator 5 to act as a cold source to cool the control unit 6.

[0040] The gas-liquid separator 5 includes a housing 502 having an end cover (top cover) 501 and a base 503. A low-pressure refrigerant inlet 504 and a low-pressure refrigerant outlet 505 are provided in the base 503. The low-pressure refrigerant inlet 504 communicates with an electronic expansion valve 3, and the low-pressure refrigerant outlet 505 communicates with the refrigerant inlet of the compressor 1. Additionally, a first riser 508 and a second riser 509 are provided on the base 503. The lower end of the first riser 508 is fixed in the base 503 and communicates with the low-pressure refrigerant inlet 504, and the upper end of the first riser 508 opens towards the end cover 501. The lower end of the second riser 509 is fixed in the base 503 and communicates with the outlet 505, and the upper end of the second riser 509 opens towards the end cover 501. The gas-liquid mixture flows in from the low-pressure refrigerant inlet 504 in the direction indicated by arrow A1, flows upward along the first riser 508, and enters the gas-liquid separator 5 through the upper opening of the first riser 508. The gas separated from the gas-liquid mixture in the gas-liquid separator 5 enters the second riser 509 through the upper opening of the second riser 509, flows downward along the second riser 509, and finally flows out from the outlet 505 in the direction indicated by arrow A2.

[0041] In this way, the low-pressure refrigerant flowing through the first riser 508 is guided and impacts the end cap 501, thereby improving the gas-liquid two-phase separation effect in the low-pressure refrigerant and enhancing the cooling effect of the low-pressure refrigerant on the control unit 6. The control unit 6, as a heat-generating unit, can transfer its heat to the low-pressure refrigerant through the end cap 1. The upper end of the second riser 509 extends to the end cap 1, allowing the low-pressure refrigerant in the gas-liquid separator 5 to be heated by the control unit 6 before entering the second riser 509, thus increasing the superheat of the refrigerant at the outlet of the gas-liquid separator 5 (i.e., the low-pressure refrigerant outlet 505).

[0042] Ports 506 and 507 are provided in the end cap 501. Heating fluid can flow into / out of the gas-liquid separator 5 through ports 506 and 507, or heating elements (such as heating wires) can be inserted into the gas-liquid separator 5 through ports 506 and 507 to heat the gas-liquid mixture in the gas-liquid separator 5.

[0043] When the gas-liquid mixture in the gas-liquid separator 5 is heated using a heating fluid, such as Figure 2D As shown, in the housing 502 of the gas-liquid separator 5 (in Figure 2DWithin the gas-liquid separator 5 (where the middle is removed), a conduit 510 is preferably provided between ports 506 and 507 to allow fluid communication between ports 506 and 507, and the wall of the conduit 510 is thermally conductive (in other words, the conduit 510 is made of a thermally conductive material) to allow the heat of the heating fluid flowing within the conduit 510 to heat the gas-liquid mixture in the gas-liquid separator 5. It is understood that the conduit 510 is optional rather than necessary when heating the gas-liquid mixture in the gas-liquid separator 5 is achieved using a heating element (e.g., a heating wire). Furthermore, the shape of the conduit 510 is not particularly limited, as long as it achieves the purpose of heating the gas-liquid mixture in the gas-liquid separator 5.

[0044] In this embodiment, exemplarily, the conduit 510 is U-shaped and extends to the bottom of the gas-liquid separator 5, so that the low-pressure refrigerant at the bottom of the gas-liquid separator 5 comes into as much contact as possible with the conduit 510. Additionally, although not shown in the figures, in another embodiment, the conduit 510 may be S-shaped or spiral-shaped, etc.

[0045] The control unit 6 includes a cover 601, a housing 603, and a printed circuit board assembly (PCBA) disposed within the housing 603. A connector 602 is electrically connected to the PCBA and extends from the housing 603. In this embodiment, both the housing 502 of the gas-liquid separator 5 and the housing 603 of the control unit 6 are made of thermally conductive material. The control unit 6 is arranged on top of the gas-liquid separator 5. In particular, the housing 603 of the control unit 6 is integrally formed with the end cap 501 on the housing 502 of the gas-liquid separator 5, so that the housing 603 of the control unit 6 fits tightly against the housing 502 of the gas-liquid separator 5, thereby forming a thermally conductive contact arrangement. This facilitates the transfer of heat from the higher-temperature control unit 6 to the lower-temperature gas-liquid separator 5, achieving the technical effect of cooling the control unit 6 through the gas-liquid separator 5.

[0046] It is understood that the control unit 6 can not only be arranged on the top of the gas-liquid separator 5 (i.e., end cap 501) as in this exemplary embodiment, but can also be arranged on the side wall of the gas-liquid separator 5, as long as a thermally conductive contact arrangement is formed between the control unit 6 and the gas-liquid separator 5.

[0047] Furthermore, one or both of ports 506 and 507 can be located on the base 503, instead of on the end cover 501 as in this embodiment. This allows for more space on the end cover 501 to accommodate the control unit 6.

[0048] Figure 2E yes Figures 2A to 2C A longitudinal sectional view of the gas-liquid separator in the thermal management assembly shown. Figure 2F yes Figures 2A to 2CThe diagram shows a three-dimensional view of the gas-liquid separator in the thermal management assembly. Figure 2F The end cap (top cover) of the gas-liquid separator was removed for the purpose of conveniently demonstrating the internal structure of the gas-liquid separator.

[0049] like Figure 2E and Figure 2F As shown, within the gas-liquid separator 5, at least between the upper opening of the first riser 508 and the upper opening of the second riser 509 (specifically... Figure 2E and Figure 2F The area indicated by arrow B is provided with a baffle 511 to prevent the refrigerant flowing into the gas-liquid separator 5 through the upper opening of the first riser 508 from flowing directly into the upper opening of the second riser 509.

[0050] Preferably, multiple baffles 511 and 513 can be provided inside the gas-liquid separator 5, and these baffles 511 and 513 intersect each other. In addition, multiple notches 512 are provided at the top and bottom of the baffles 511 and 513 to allow refrigerant to pass through. In this way, the flow path of the refrigerant in the gas-liquid separator 5 is extended (instead of flowing directly into the upper opening of the second riser 509 through the upper opening of the first riser 508), thereby enabling more sufficient contact and heat exchange with the conduit 510, which helps to separate the gas and liquid phases of the low-pressure refrigerant.

[0051] Figure 3 This is a perspective view of a thermal management component according to another exemplary embodiment of the present invention. Figure 3 The illustrated embodiments and Figures 2A to 2C The main difference in the illustrated embodiment is that the housing 603 of the control unit 6 and the end cap 501 of the gas-liquid separator 5 are integrally formed; that is, the housing 603 and the end cap 501 are integrally formed parts rather than assembled parts. This is beneficial for improving the heat exchange efficiency between the control unit 6 and the gas-liquid separator 5.

[0052] Figure 4 This is an architecture diagram of a thermal management system according to yet another exemplary embodiment of the present invention.

[0053] like Figure 4 As shown, along the direction of refrigerant flow ( Figure 4 (As indicated by the black arrow in the diagram), the refrigerant circuit sequentially includes a compressor 1, a water-cooled condenser 2, an electronic expansion valve 3, an evaporator 4, and a gas-liquid separator 5. The control unit 6 is communicatively connected to the compressor 1, the electronic expansion valve 3, and components such as a water pump, water valve, shut-off valve, and sensors (not shown) to control the thermal management system. In other words, the basic architecture of the thermal management system according to this exemplary embodiment is... Figure 1AThe basic architectures of the illustrated thermal management systems are generally similar. The main difference lies in that, in this exemplary embodiment, the high-pressure refrigerant condensed by the water-cooled condenser 2 is used as the heating fluid. This heating fluid is directed to flow in from port 506 of the gas-liquid separator 5, through conduit 510, and out of the gas-liquid separator 5 via port 507, thereby heating the gas-liquid mixture in the gas-liquid separator 5 to allow heat exchange between the high-pressure refrigerant and the low-pressure refrigerant within the gas-liquid separator 5. This allows for better utilization of the residual heat of the condensed refrigerant (without requiring or only requiring the auxiliary introduction of other heat sources) to heat the gas-liquid mixture in the gas-liquid separator 5; in other words, it allows the gas-liquid separator 5 to be used as a cold source to cool the refrigerant.

[0054] In this configuration, port 506 can be used as a high-pressure refrigerant inlet, and port 507 as a high-pressure refrigerant outlet. Alternatively, port 506 can be used as a high-pressure refrigerant outlet, and port 507 as a high-pressure refrigerant inlet.

[0055] The purpose of introducing high-pressure refrigerant as a heating fluid into the gas-liquid separator 5 is to cause more of the high-pressure refrigerant to condense into liquid refrigerant or to increase the subcooling of the high-pressure refrigerant; at the same time, to cause as much of the liquid refrigerant in the low-pressure refrigerant as possible to vaporize, or to increase the superheat of the low-pressure refrigerant (when all the low-pressure refrigerant in the gas-liquid separator 5 is in a gaseous state). This significantly improves the performance of the thermal management system.

[0056] It is understood that the thermal management system according to this utility model is applicable to various motor vehicles.

[0057] Although the technical objectives, solutions, and effects of this utility model have been described in detail above with reference to specific embodiments, it should be understood that the above embodiments are merely exemplary and not restrictive. Any modifications, equivalent substitutions, or improvements made by those skilled in the art within the essential spirit and principles of this utility model are included within the protection scope of this utility model.

Claims

1. A thermal management component, comprising a gas-liquid separator (5) and a control unit (6), characterized in that, The gas-liquid separator (5) and the control unit (6) are constructed as one unit to allow the gas-liquid separator (5) to act as a cold source to cool the control unit (6).

2. The thermal management component according to claim 1, characterized in that, The gas-liquid separator (5) and the control unit (6) are assemblies or integrally molded parts.

3. The thermal management component according to claim 1 or 2, characterized in that, The housing (502) of the gas-liquid separator (5) and the housing (603) of the control unit (6) are both made of thermally conductive material, and the housing (603) of the control unit (6) is attached to the housing (502) of the gas-liquid separator (5).

4. The thermal management component according to claim 3, characterized in that, The housing (603) of the control unit (6) is integrally formed with the end cap (501) on the housing (502) of the gas-liquid separator (5).

5. The thermal management component according to claim 3, characterized in that, A printed circuit board assembly (PCBA) is provided inside the housing (603) of the control unit (6).

6. The thermal management component according to claim 1, characterized in that, The control unit (6) is assembled to the gas-liquid separator (5) by bolts, adhesives, welding or snaps.

7. The thermal management component according to claim 4, characterized in that, The gas-liquid separator (5) has a base (503) in which a low-pressure refrigerant inlet (504) and a low-pressure refrigerant outlet (505) are provided.

8. The thermal management component according to claim 7, characterized in that, The end cap (501) is provided with a high-pressure refrigerant inlet (506) and a high-pressure refrigerant outlet (507), and A conduit (510) is provided between the high-pressure refrigerant inlet (506) and the high-pressure refrigerant outlet (507) to allow the high-pressure refrigerant inlet (506) and the high-pressure refrigerant outlet (507) to be in fluid communication with each other, and the wall of the conduit (510) is thermally conductive to allow the high-pressure refrigerant flowing in the conduit (510) to exchange heat with the low-pressure refrigerant in the gas-liquid separator (5).

9. The thermal management component according to claim 8, characterized in that, A first riser (508) is provided on the base (503). The lower end of the first riser (508) is fixed in the base (503) and communicates with the low-pressure refrigerant inlet (504). The upper end of the first riser (508) opens toward the end cap (501). A second riser (509) is provided on the base (503). The lower end of the second riser (509) is fixed in the base (503) and communicates with the low-pressure refrigerant outlet (505). The upper end of the second riser (509) opens toward the end cap (501).

10. The thermal management component according to claim 9, characterized in that, A baffle (511) is provided in the gas-liquid separator (5) at least between the upper opening of the first riser (508) and the upper opening of the second riser (509) to prevent the refrigerant flowing into the gas-liquid separator (5) through the upper opening of the first riser (508) from flowing directly into the upper opening of the second riser (509).

11. The thermal management component according to claim 10, characterized in that, A plurality of baffles (511) are provided in the gas-liquid separator (5), and a notch (512) is provided in the baffle (511) to allow refrigerant to pass through.

12. A thermal management system having a refrigerant circuit and a control unit (6), wherein a gas-liquid separator (5) is arranged in the refrigerant circuit, characterized in that, The thermal management system includes a thermal management component according to any one of claims 1 to 11.

13. The thermal management system according to claim 12, characterized in that, Along the flow direction of the refrigerant, the refrigerant circuit sequentially includes a compressor (1), a condenser (2), an electronic expansion valve (3), an evaporator (4), and the gas-liquid separator (5).

14. The thermal management system according to claim 12, characterized in that, The control unit (6) is communicatively connected to the components of the thermal management system to control the thermal management system, the components including a compressor (1), an electronic expansion valve (3), and / or a sensor.

15. A motor vehicle, characterized in that, The motor vehicle includes a thermal management system according to any one of claims 12 to 14.

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