Thermal management module and method for mounting a thermal management module in a vehicle

Abstract

The invention relates to a thermal management module (10), in particular a coolant and / or refrigerant management module for handling a fluid, in particular a coolant and / or refrigerant, within a vehicle (14), in particular an electric vehicle, comprising at least one central fluid distribution unit (18) and a plurality of components (16a, 16b, 16c, 16d) arranged on the fluid distribution unit (18), in particular at least one pump and / or a valve. It is proposed that the thermal management module (10) has a first mounting point (40) for pluggable mounting of the thermal management module in the vehicle (14).

Description

State of the art

[0001] A thermal management module for fluidically coupling components of a vehicle, in particular an electric vehicle, has already been proposed, comprising at least one distribution unit and a component interface arranged on the distribution unit for fluidically connecting a component of the vehicle to the distribution unit. It is also known to connect components, such as pumps and valves, to a distribution unit. Disclosure of the invention

[0002] The invention is based on a thermal management module, in particular a coolant and / or refrigerant management module for handling a fluid, in particular a coolant and / or refrigerant, within a vehicle, in particular an electric vehicle, having at least one central fluid distribution unit and a plurality of components arranged on the fluid distribution unit, in particular at least one pump and / or one valve. It is proposed that the thermal management module have a first fastening point for pluggable fastening of the thermal management module in the vehicle.

[0003] The thermal management module according to the invention has the advantage that assembly effort can be significantly reduced. Particularly advantageously, the screw connection otherwise required on the thermal management module can be replaced by a simple plug connection. A major advantage is that the same advantages as with the screw connection are still available, in particular that not only forces but also torques from the thermal management module can be transmitted to the vehicle or body. This ensures that the thermal management module is optimally supported on the vehicle, thus minimizing any movement of the thermal management module relative to the vehicle.

[0004] The advantage of the present invention lies in the safe and efficient handling and installation of thermal management modules, which, due to their high component integration, can have a correspondingly high weight of several kilograms. In many manufacturing plants, especially in OEM environments, assembly line workers are often under extreme time pressure to install these units in vehicles. The plug-in connection enables particularly simple pre-assembly in a first fastening point. Due to the simple plug-in installation of the thermal management module, the assembly effort for the OEM can be significantly reduced. Furthermore, the plug-in fastening offers the advantage that the installation direction can be designed horizontally.

[0005] The thermal management module is preferably provided for a vehicle, in particular an electric vehicle. The vehicle is preferably designed as a battery-powered and / or fuel cell-powered vehicle. Compared to vehicles equipped exclusively with combustion engines, the available space is limited due to the required energy storage units, electric motors, control electronics, and other components. At the same time, the number of heat sources that must be cooled, such as energy storage units, electric motors, control electronics, and inverters, increases. This leads to an increased complexity of the thermal management system, which in turn leads to an exponentially increasing space requirement due to the necessary fluid lines.

[0006] The thermal management module of the type in question here preferably has a central fluid distribution unit, which forms the core element of the fluid circuit and integrates a plurality of pumps and / or valves of the fluid circuit. For example, a valve could be provided to direct the flow of a coolant. For example, a pump could be provided to move and / or accelerate and / or circulate a coolant. In the thermal management module, the fluid distribution unit serves as a distribution or collection point for the fluid, in particular the coolant or refrigerant, within the fluid circuit. The components are preferably arranged on an outer surface of the fluid distribution unit and protrude at least partially beyond the contour of the fluid distribution unit.

[0007] The main function of the fluid distribution unit is to control the flow of fluid and direct it to various parts of the vehicle, such as the engine, the radiator, heating or cooling elements, and other components that require temperature regulation. According to an advantageous development of the invention, the fluid distribution unit has a plurality of fluid handling elements, in particular fluid channels and / or fluid inlet and outlet ports, to distribute the fluid to various areas within the thermal management system.

[0008] A "thermal management module" is to be understood in particular as an assembly which performs a cooling function, in particular at least partially, wherein the carrier fluid is designed as a coolant and / or refrigerant. In particular, the coolant is intended to absorb and transport heat away from the component to be cooled, in particular the drive. In particular, the thermal management module forms a single, prefabricated component with which preferably all components included in the thermal management module can be installed in the vehicle in a common assembly step. In particular, the thermal management module can be delivered in one piece to a vehicle assembly line. However, it is also conceivable for the thermal management module to be designed to be expandable or separable, at least in part.In particular, the thermal management module features defined interfaces designed for installation with suitable counterparts and / or suitable mounts of the respective vehicle. In particular, the thermal management module is designed for plug-and-play installation.

[0009] Preferably, the components to be cooled, such as an electric motor and / or a battery and / or a housing of the motor to be cooled, in particular an electric motor and / or an entire drive train or the like, are connected to the thermal management module at least via the cooling circuit. Preferably, the fluid distribution unit at least partially forms a housing of the thermal management module. Preferably, the thermal management module has a plurality of components arranged on the fluid distribution unit. Preferably, the components are designed as pumps and / or valves. Preferably, the components are fluidly connected to one another via the fluid handling elements of the fluid distribution unit.

[0010] The fluid distribution unit is preferably provided to distribute the coolant in at least one cooling circuit and, alternatively or additionally, also the refrigerant in at least one refrigerant and / or to enable control and / or regulation of different cooling circuits. The fluid distribution unit preferably has a plurality of connections, in particular for distributing the coolant and / or refrigerant. The connections are preferably provided to connect one and / or more cooling circuits and / or refrigerant circuits to the thermal management module. In particular, the fluid distribution unit is provided to guide and / or distribute coolant and / or refrigerant, in particular in a closed circuit. The fluid distribution unit is preferably formed at least partially from a plastic. It is conceivable for the fluid distribution unit to have insulation.Preferably, the fluid distribution unit is manufactured at least partially as a plastic injection-molded part.

[0011] According to an advantageous development, a particularly easy-to-manufacture, lightweight thermal management module can be provided in that the fluid distribution unit is at least partially formed from plastic. The fluid distribution unit is preferably made of plastic and is produced, for example, by means of a plastic injection molding process. The fluid distribution unit preferably has a fluid distribution element base and a fluid distribution element cover, which are connected to one another in such a way that the internal fluid space of the fluid distribution unit is formed or delimited. The fluid distribution unit preferably has fluid handling elements, in particular fluid channels. The fluid distribution element base and / or the fluid distribution element cover preferably have structures that form the fluid handling elements inside the fluid distribution unit.Preferably, a fluid handling element is formed by connecting a fluid distribution element base and a fluid distribution element cover as a circumferentially closed fluid guide. Preferably, the at least one fluid handling element is formed circumferentially by the housing of the fluid distribution unit or sealed from other components in an interior space of the fluid distribution unit.

[0012] A particularly simple connection of the fluid distribution element base and the fluid distribution element cover can be provided in particular by the fluid distribution element base and the fluid distribution element cover being connected in a substantially fluid-tight manner by means of welding, in particular by means of heating element welding, to form the fluid handling element.

[0013] According to a particularly advantageous development of the invention, the first fastening point comprises at least one plug element for pluggable fastening of the thermal management module in a first plug receptacle of the vehicle. However, it is also conceivable for the thermal management module itself to have the plug receptacle into which a plug element arranged on the vehicle can be inserted.

[0014] In addition to the first fastening point, according to an advantageous development of the invention, the thermal management module has at least one second, preferably additionally a third, fastening point, which are designed as screw connection points for screwing the thermal management module into the vehicle. The three fastening points of the thermal management module can particularly advantageously absorb all forces and moments. A connection optimized with regard to the force-stress distribution can be provided in particular by arranging the fastening points on the thermal management module at a maximum distance from one another in the sense of a three-point fastening. The fastening points are preferably arranged on the fluid distribution unit.

[0015] A particularly easy-to-manufacture plug-in element can be provided in particular by arranging the plug-in element on the fluid distribution unit, preferably forming a one-piece connection with the fluid distribution unit. The plug-in element is preferably injection-molded onto the fluid distribution unit using a plastic injection molding process.

[0016] A particularly stable and at the same time easy-to-install thermal management module can be provided in particular by the plug-in element being designed as a snap-in connection element, wherein the plug-in element preferably has at least one locking bolt which can be inserted into a plug-in receptacle on the body and which has a locking lug for locking in the plug-in receptacle.

[0017] An optimized introduction of force into the body can be provided in particular by the plug-in receptacle of the body being designed in the shape of an elongated hole, wherein the contour of the locking bolt of the plug-in element is designed to be essentially congruent in shape, in particular corresponding to the plug-in receptacle.

[0018] To enlarge the active surface pairs for a positive connection, an advantageous development of the invention can provide for the locking bolt to be contoured on its outer surface, in particular corrugated or serrated. Preferably, the plug-in receptacle has an inner wall corresponding to the contouring of the outer surface of the locking bolt, so that the outer surface of the locking bolt and the inner wall of the plug-in receptacle interlock.

[0019] In order to dampen the noise and vibration transmission between the thermal management module and the body, it can be provided according to an advantageous further development that a damping element, in particular a rubber buffer, preferably an EPDM buffer, is arranged between the plug-in receptacle and the plug-in element.

[0020] To mount the thermal management module in the vehicle, the plug-in element of the thermal management module is first inserted into a socket in the vehicle at a first mounting point. The thermal management module is then secured in place by screwing the first screw element into a second mounting point in the vehicle. The remaining degree of freedom of the thermal management module is then reduced by screwing the second screw element into a third mounting point in the vehicle. drawing

[0021] Further advantages will become apparent from the following description of the drawings. The drawings illustrate two exemplary embodiments of the invention. The drawings, the description, and the claims contain numerous features in combination. Those skilled in the art will also expediently consider the features individually and combine them into useful further combinations.

[0022] They show: Fig. 1 A schematic representation of a vehicle with a thermal management module, Fig. 2 a schematic representation of a thermal management module, Fig. 3a a first fastening point on a vehicle in a sectional view Fig. 3b a representation of a cross section of a first fastening point. Description of the embodiments

[0023] The Fig. 1 shows a schematic representation of a vehicle 14. The vehicle 14 is designed as a car and / or truck and / or construction vehicle and / or comparable vehicle 14. The vehicle 14 has an electric drive unit 36. The electric drive unit 36 ​​includes an electric motor. The electric drive unit 36 ​​includes a battery. The drive unit 36 ​​could include further components of the electric drive unit 36, such as an entire drive train or individual components of the drive train. Alternatively, the vehicle 14 could also have an internal combustion engine or a hybrid drive as the drive unit 36. The vehicle 14 has a cooling and / or refrigerant circuit 12.

[0024] According to an advantageous development of the invention, the cooling and / or refrigerant circuit 12 is partially formed by a thermal management module 10. The cooling and / or refrigerant circuit 12 with the thermal management module 10 is intended at least to cool the drive unit 36 ​​of the vehicle 14. The thermal management module 10 is designed as a complete assembly that can be mounted in the vehicle 14.

[0025] In Fig. 2 shows an embodiment of such a thermal management module 10. The thermal management module 10 has at least one, preferably a plurality of, integrated components 16a, 16b, 16c. The components 16a, 16b, 16c can be designed, for example, as a coolant pump and / or coolant valve. The thermal management module 10 preferably has a plurality of components 16a, 16b, 16c. The components 16a, 16b, 16c are preferably connected to a fluid distribution unit 18, which can also be referred to as a manifold. The fluid distribution unit 18 is preferably designed to distribute the fluid between the components 16a, 16b, 16c and corresponding inlets and outlets of the fluid distribution unit 18. The fluid distribution unit 18 is designed as a central element to which the corresponding components 16a, 16b, 16c are directly arranged and fastened.

[0026] The thermal management module 10 according to the Fig. The embodiment of the invention shown in Figure 2 is designed as a coolant management module and has a central fluid distribution unit 18 and components 16a, 16b, 16c arranged or fastened thereto.

[0027] According to the Fig. In the embodiment of the invention shown in Figure 2, two pumps 16a, 16b and a valve 16c are attached, in particular screwed, to the fluid distribution unit. The components 16a, 16b, 16c extend beyond the contour of the fluid distribution unit 18. The components 16a, 16b, 16c are preferably at least partially connected to one another by means of electrical connecting elements, in particular via corresponding cable harnesses arranged outside the fluid distribution unit 18. For reasons of clarity, the cable harnesses are shown in Fig. 2 not shown.

[0028] The fluid distribution unit 18 preferably has a fluid distribution element base 19 (here on the rear side of the thermal management module 10) and a fluid distribution element cover 20. The fluid distribution unit 18 is preferably formed at least partially from a plastic material. The fluid distribution unit 18 is preferably formed at least partially as a plastic injection-molded part. Both the fluid distribution element base 19 and the fluid distribution element cover 20 are preferably each formed in one piece. The fluid distribution element base 19 and the fluid distribution element cover are preferably connected to one another by welding, in particular by hot-tool welding, such that at least one fluidically closed fluid channel is created between the fluid distribution element base 19 and the fluid distribution element cover 20. The fluid distribution element base and / or the fluid distribution element cover are preferably designed as half-shells.

[0029] Due to the high integration of components in a common thermal management module 10, the module has a correspondingly high weight.

[0030] For fastening the thermal management module 10 in the vehicle 14, the thermal management module 10 has, in accordance with the Fig. 2, the thermal management module 10 has a first fastening point 40. The first fastening point 40 is designed to be connected to the vehicle 14 as a plug-in connection. In addition to the first fastening point 40, the thermal management module 10 has two further fastening points, a second fastening point 42a and a third fastening point 42b. The second and third fastening points 42a, 42b are preferably each designed as screw connections to the vehicle 14. According to the Fig. In the embodiment of the invention shown in Figure 2, the fastening points 40, 42a, 42b are each arranged on the fluid distribution element 18. Preferably, the fastening points 40, 42a, 42b are each arranged at a maximum distance from each other in the sense of a three-point fastening on the thermal management module 10.

[0031] As in Fig. 2, the first fastening point 40 has a plug-in element 44. The plug-in element 44 is preferably formed integrally with the fluid distribution unit 18. The plug-in element 44 is preferably formed as a plastic injection-molded part and is preferably injection-molded onto the fluid distribution unit 18. According to the Fig. In the embodiment of the invention shown in Figure 2, the plug element 44 is designed as a snap-in connection element and preferably has at least one locking bolt 46 which can be inserted into a plug receptacle on the body of the vehicle 14 and has a locking lug 48 for locking in the plug receptacle.

[0032] When installing the thermal management module 10 in the vehicle 14, the plug-in element 44 is first inserted into a plug-in receptacle on the vehicle 14 at the first fastening point 40. The thermal management module is then secured to the vehicle 14 by screwing the second fastening point 42a of the thermal management module 10. The remaining degree of freedom is then reduced by screwing the thermal management module 10 into the third fastening point 42b on the vehicle.

[0033] In Fig. 3a shows a simplified sectional view of a first attachment point 40 between the vehicle 14 and the thermal management module 10. As shown in Fig. As can be seen in Figure 3a, the plug element 44 is integrally connected to the fluid distribution unit 18. The plug element 44 has a locking bolt 46 and a locking element 48. Preferably, the locking bolt 46 and locking element 48 are integrally formed. The locking element 48 is preferably designed as a locking lug and protrudes beyond the contour of the locking bolt 46 for a positive connection to the plug receptacle 60 of the vehicle body 14.

[0034] In Fig. 3b shows a top view of the plug-in receptacle 60 of the vehicle 14 with the plug-in element 44 inserted. According to the Fig. In the embodiment of the invention shown in Figure 3b, the plug-in receptacle 60 of the vehicle 14, in particular of the body of the vehicle 14, is formed in a slot-shaped cross-section. The plug-in element 44 engages in the slot-shaped plug-in receptacle 60. According to the embodiment shown in Fig. In the embodiment of the invention shown in Figure 3b, the locking bolt has a cross-section that is congruent with the elongated hole-shaped plug-in receptacle 60 and is thus designed to correspond substantially to the plug-in receptacle 69. A damping element 64 can be arranged in the plug-in receptacle 60. The damping element 64 is preferably designed to be inserted into the plug-in receptacle 60. The damping element 64 preferably surrounds the plug-in receptacle 60 all the way around. The damping element 64 is preferably designed as a rubber buffer, preferably as an EPDM buffer. The damping element 64 preferably has a corresponding recess 68 in the center for receiving the plug-in element 44.

[0035] As in Fig.As can be seen in Figure 3a, according to an advantageous development of the invention, the damping element 64 can have a substantially pot-shaped first section 70 and a circumferential collar 72 formed thereon. The circumferential collar 72 preferably rests against the plug-in receptacle 60. The plug-in receptacle 60 and / or the damping element 64 preferably have an axial stop 80, which limits the insertion position of the plug-in element 44 in the axial direction.

[0036] According to a particularly advantageous development of the invention, it can be provided that the locking bolt 46 is contoured, in particular corrugated, wherein the plug-in receptacle 60 has an inner wall which is correspondingly corrugated, so that a correspondingly pre-locking connection can be provided due to the toothing of the inner wall of the plug-in receptacle 60 and the locking bolt 46.

Claims

[1] Thermal management module (10), in particular a coolant and / or refrigerant management module for handling a fluid, in particular a coolant and / or refrigerant within a vehicle (14), in particular an electric vehicle, with at least one central fluid distribution unit (18) and a plurality of components (16a, 16b, 16c, 16d) arranged on the fluid distribution unit (18), in particular at least one pump and / or one valve, characterized by that the thermal management module (10) has a first fastening point (40) for pluggable fastening of the thermal management module in the vehicle (14). [2] Thermal management module (10), characterized by that the first fastening point (40) has at least one plug-in element (44) for pluggable fastening of the thermal management module (10) in a plug-in receptacle (60) of the vehicle (14). [3] Thermal management module (10) according to claim 1, characterized bythat the thermal management module (10) has at least one second, preferably additionally a third fastening point (42a, 42b), which is designed as screw connection points for screwing the thermal management module (10) in the vehicle (14). [4] Thermal management module (10) according to one of the preceding claims, characterized by that the first, second and third fastening points (40, 42a, 42b) are each arranged at a maximum distance from one another in the sense of a three-point fastening on the thermal management module (10), in particular on the fluid distribution unit (18). [5] Thermal management module (10) according to one of the preceding claims, characterized by that the fluid distribution element (18) essentially comprises at least partially plastic, in particular is produced by means of a plastic injection molding process. [6] Thermal management module (10) according to one of the preceding claims, characterized bythat the plug-in element (44) is arranged on the fluid distribution unit (18), preferably formed integrally with the fluid distribution unit (18). [7] Thermal management module (10) according to one of the preceding claims, characterized by that the plug-in element (44) is designed as a latching connection element, wherein the plug-in element (44) preferably has at least one locking bolt (46) which can be inserted into the plug-in receptacle (60) and which has a latching element (48), in particular a latching nose for latching in the plug-in receptacle (60). [8] Thermal management module (10) according to one of the preceding claims, characterized by that the plug-in receptacle (60) is designed in the shape of an elongated hole, wherein the contour of the locking bolt (46) of the plug-in element (44) is designed to be substantially congruent in shape with the plug-in receptacle (60). [9] Thermal management module (10) according to one of the preceding claims, characterized bythat the locking bolt (46) is contoured, in particular corrugated and / or serrated, wherein the plug-in receptacle (60) has an inner wall which is contoured to correspond to the positive toothing. [10] Thermal management module (10) according to one of the preceding claims, characterized by that a damping element (64), in particular a rubber buffer, preferably an EPDM buffer, is arranged between the plug-in receptacle (60) and the plug-in element (44), in particular the locking bolt (46). [11] Method for fastening a thermal management module (10) according to one of the preceding claims in a vehicle (14), comprising the following method steps: - inserting a plug-in element (44), in particular the locking bolt (46) of the thermal management module (10) or of the vehicle (14) into a plug-in receptacle (60) of the vehicle (14) or of the thermal management module (10) in a first fastening point (40), - locking the thermal management module (10) by screwing it to the vehicle (14) in a second fastening point (42a), - Reduction of the remaining degree of freedom of the thermal management module (10) by screwing it to the vehicle (14) in a third fastening point (42b).

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