Coolant tank, pump module and charging unit

Abstract

The present invention relates to a coolant tank (1) for a pump module (2) comprising a tank container (3) and a tank lid (4) covering the tank container. The essential feature of the invention is that the tank container (3) is designed as a supporting component for at least one coolant pump (5) and that the tank lid (4) is designed as a functional carrier and has at least one connection point (8) for a sensor device (9). This can result in a significant reduction in installation space.

Description

[0001] The present invention relates to a coolant tank for a pump module comprising a tank container and a tank lid covering the tank container according to the preamble of claim 1. The invention further relates to a pump module comprising such a coolant tank and a charging device comprising such a pump module.

[0002] Coolant tanks of this type for pump modules are known per se, with such coolant tanks, particularly in stationary charging equipment such as charging stations for electric or hybrid vehicles, being arranged inside the charging equipment via corresponding brackets or support frames. In this arrangement, for example, the coolant tank or individual coolant pumps, as well as corresponding sensors or control units, are each individually fixed to the support frame or to other components inside the charging equipment housing. This has the significant disadvantage that such pump modules, including the support frame, coolant tank, and coolant pump, require a considerable amount of installation space.

[0003] Another disadvantage of known pump modules lies particularly in the arrangement of corresponding connections for sensors, for example pressure and temperature sensors.

[0004] The present invention therefore deals with the problem of providing an improved or at least alternative embodiment for a coolant tank for a pump module of the generic type, by means of which the disadvantages known from the prior art can be overcome at least partially.

[0005] This problem is solved according to the invention by the subject matter of independent claim 1. Advantageous embodiments are the subject matter of the dependent claims.

[0006] The present invention is based on the general concept of no longer merely using a coolant tank for a pump module as a storage container for coolant, but also assigning it functions that, for example, eliminate the need for a previously required support frame and allow for a significantly more compact design. The coolant tank for a pump module according to the invention comprises a tank container and a tank lid covering it, which are, for example, tightly screwed together via a seal. According to the invention, the tank container is designed as a supporting component for at least one coolant pump and thus replaces the previously required support frame, while the tank lid is designed as a functional element and has at least one connection point for a sensor device, thereby enabling further functions, such as the integration of such a sensor device.The design of the tank cap as a functional element means that it has corresponding connection points, in particular electrical, data-transmitting, and / or fluid-transmitting connection points, which enable at least a direct connection of a sensor device, especially a pressure or temperature sensor, so that these required sensors do not have to be attached separately to a support frame as is currently customary. By functionally integrating such a sensor device into the tank cap via the at least one connection point of the coolant tank according to the invention, not only can a particularly space-optimized design be achieved, but also a reduction in the number of parts, thereby reducing storage and logistics costs and consequently also assembly costs.Furthermore, by designing the tank cap as a functional element with corresponding connection points, it is possible to position appropriate sensors in ideal locations.

[0007] In an advantageous embodiment of the coolant tank according to the invention, the sensor device comprises a pressure sensor and / or a temperature sensor. The at least one connection point provided according to the invention can, for example, have an internal thread via which a corresponding sensor device with a complementary external thread can be easily screwed onto the tank cap. This provides a simple and leak-proof mounting option, whereby the provision of corresponding connection points can also refer to an electrical connection point or a data transmission connection point. To enable particularly reliable fixation, for example of the sensor device to the tank cap, threaded metal sleeves cast into the plastic of the tank cap can also be provided.

[0008] The tank should ideally have at least one receptacle for a coolant pump. This receptacle can be a recess or a C-shaped recess that at least partially, and preferably more than half, encompasses the coolant pump, allowing it to be snapped or clipped into place. This type of receptacle makes it possible to fix the coolant pump directly to the tank, which acts as a load-bearing component, without the need for separate brackets, angles, or screws to attach it to a support frame. The tank is designed to be sufficiently rigid to serve as a load-bearing component for the coolant pump.

[0009] Ideally, at least one mounting point should be formed integrally with the tank. This offers the significant advantage, particularly if the tank is manufactured as an injection-molded plastic part, that the mounting point is not only reliably fixed to the tank but can also be produced in a single manufacturing step. Furthermore, the integral formation of the mounting point with the tank eliminates the need for separate mounting of the mounting point to the tank, thus reducing not only the number of parts required but also storage, logistics, and assembly costs.

[0010] In a particularly preferred embodiment of the coolant tank according to the invention, the tank container and / or the tank cap are designed as injection-molded plastic parts. This offers the significant advantage of virtually unlimited design freedom as well as cost-effective and high-quality manufacturing. Furthermore, strength properties can be determined relatively easily by selecting appropriate plastics for the tank container or the tank cap. To further support the load-bearing function of the tank container, it can also be provided that the tank container has stiffening structures, such as fibers and / or metallic inserts, thereby increasing the strength and rigidity of the tank container without adding much weight.

[0011] In a further advantageous embodiment of the coolant tank according to the invention, the tank container has a level indicator and / or molded-on connection ports for coolant. Such a level indicator can, for example, be created by a transparent plastic that is arranged in a specific area of ​​the tank container and is provided with a scale. In this case, the tank container is then, for example, designed as a two-component injection-molded plastic part with two different plastics, namely, for example, a non-transparent plastic for the tank container and an at least partially transparent plastic in the area of ​​the level indicator.

[0012] Additionally or alternatively, the tank can also have molded-on connection ports for coolant, so that, for example, a coolant pump is not only fixed directly to the tank but can also be directly connected to it via these ports for fluid transfer. Such connection ports can be designed as plugs or couplings, for example, and allow for a relatively simple, fluid-tight connection of a coolant pump by simply plugging it in.

[0013] The present invention is further based on the general concept of providing a pump module with a coolant tank as described in the preceding paragraphs and at least one coolant pump. This allows the advantages described for the coolant tank to also be applied to the pump module. Specifically, these advantages lie in the fact that the pump module comprises not only a coolant tank but also the coolant pump arranged on the coolant tank's reservoir, so that the pump module can be manufactured, for example, as a prefabricated assembly. Such a prefabricated pump module can then be installed directly, for example, in the interior of a charging device's housing, without the need for additional components, such as support frames, as were previously required.Due to the design of the tank lid as a functional carrier and the tank container as a load-bearing component, the pump module according to the invention not only reduces the variety of parts but also reduces the required installation space.

[0014] It is advantageous to install a sensor device, in particular a temperature or pressure sensor, at at least one connection point on the tank cap. This single connection point allows for the simple and direct mounting of a sensor device, such as a pressure or temperature sensor, directly on the tank cap, thus significantly increasing its functionality. A further advantage of directly arranging such sensors on the tank cap's connection points is that the sensors can be ideally positioned. Of course, additional connection points can also be provided on the tank cap, to which, for example, electrical or data-transmitting components can be connected.

[0015] In a further advantageous embodiment of the pump module according to the invention, a heating device for heating the coolant is arranged on the tank. The heating device is directly attached to the tank, which serves as a load-bearing component, in particular by bolting it on, thus eliminating the need for separate fixing of the heating device to, for example, a previously required support frame. The coolant can therefore be heated via the heating device.

[0016] In a particularly preferred embodiment of the pump module according to the invention, the module includes a control unit that is fixed to the tank or the tank cap of the coolant tank. Depending on the size and thus also the weight of the control unit, it can be arranged on the tank, which is designed as a load-bearing component, or alternatively on the tank cap, which is designed as a functional carrier. Such a control unit can, for example, control the coolant pump or the heating element, and can, of course, also receive corresponding input data from, for example, the sensor device. For this reason, the control unit is connected to, preferably, the coolant pump, the sensor device, the heating element, and / or the level indicator.If other electrical components are present, these can of course also be connected to the control unit.

[0017] The present invention is further based on the general idea of ​​equipping a charging device with a pump module as described in the previous paragraphs.

[0018] The control unit processes data supplied by relevant sensors and can determine the current operating status, such as a cold start, normal operation, boost mode, or emergency mode. Special time modes, such as night mode or silent mode, can also be controlled or switched. A safety circuit can also be activated. The control unit can also regulate the output of the coolant pump and / or a fan to predefined target values, which can thus be controlled depending on the current charging power. The temperature sensor can also measure the coolant temperature, allowing conclusions to be drawn about its viscosity. If malfunctions or errors are detected, the control unit can transmit a corresponding error signal to, for example, an external charging station.

[0019] Further important features and advantages of the invention will become apparent from the dependent claims, the drawings and the associated description of the figures based on the drawings.

[0020] It is understood that the features mentioned above and those to be explained below can be used not only in the combinations specified, but also in other combinations or individually, without departing from the scope of the present invention. The components of a higher-level unit, such as a device, apparatus, or arrangement, mentioned above and those to be mentioned below, which are designated separately, can form separate parts or components of this unit or be integral areas or sections of this unit, even if this is depicted differently in the drawings.

[0021] Preferred embodiments of the invention are shown in the drawings and are explained in more detail in the following description, wherein identical reference numerals refer to identical or similar or functionally identical components.

[0022] Each of these shows, schematically, Fig. 1 a view of a coolant tank according to the invention, Fig. 2 a representation as in Fig. 1, however from a different perspective, Fig. 3 a view of a pump module according to the invention with a coolant tank according to the invention as well as with various sensors, a coolant pump and a control unit, Fig. 4 a representation as in Fig. 3, but from a different perspective, Fig. 5 a representation as in Fig. 4, but with two coolant pumps, Fig. 6 a representation as in Fig. 5, however from a different perspective, Fig. 7 a top view of the pump module according to the invention.

[0023] According to the Fig. Figures 1 to 6 show a coolant tank 1 according to the invention for a pump module 2 (compare the Fig. 3 - 7) a tank 3 and a tank cap 4 tightly connected to and covering the tank 3. The tank 3 is designed as a load-bearing component, while the tank cap 4 is designed as a functional element. This offers the significant advantage that, for example, further attachments, specifically a coolant pump 5 (compare the Fig. 3 - 6) but also a heating device 6 can be mounted directly on the tank container 3. Of course, a type of frame 7 (compare the Fig. 3 - 6) are provided, which is firmly connected to the tank container 3 designed as a load-bearing component and also serves as a support for, for example, the coolant pump 5 or for connecting the tank container to a body.

[0024] By designing the tank lid 4 as a functional carrier, a large number of previously separately installed components, such as sensor devices, can now be integrated directly into the tank lid 4, thereby significantly reducing the installation space requirement and achieving an overall particularly compact design of the pump module 2 according to the invention.

[0025] The tank cap 4 has at least one connection point 8, according to the Fig. 1-7 a multitude of such connection points 8 to which a sensor device 9, in particular a pressure sensor or a temperature sensor 11, can be easily connected. A vent screw 12 or electrical connections 13, for example for supplying power to the coolant pump 5, can of course also be connected via such a connection point 8. By integrating, for example, the pressure sensor(s), the temperature sensors 11, the vent screw 12, and various electrical connections 13 into the tank cap 4, separate components for securing such connections can be eliminated, resulting not only in a significant space saving but also in a significant assembly advantage.

[0026] If one considers in particular the Fig. 1, Fig. From figures 2 and 4, it can be seen that the tank 3 has at least one receptacle 14, here two receptacles 14, for a coolant pump 5. These receptacles 14 make it possible, depending on requirements, to use either only a single coolant pump 5, as is the case according to the Fig. 3 and Fig. 4 is shown, or alternatively two coolant pumps 5, as shown in the Fig. 5 and Fig. As shown in Figure 6, the coolant pump 5 is to be fixed to the tank 3. For this purpose, the mounts 14 can be designed as so-called C-shaped mounts and at least partially encompass the associated coolant pump 5. The coolant pump 5 is then fixed in the respective mount 14, for example, by means of a hose clamp 15.

[0027] Furthermore, the receptacle 14 can, for example, be formed in one piece with the tank container 3, thus eliminating the need for both separate manufacturing and subsequent assembly of the receptacle 14 on the tank container 3.

[0028] The tank container 3 can, for example, be manufactured as a plastic injection-molded part, which allows it to be produced not only cost-effectively but also with high quality. With a suitably designed plastic injection molding process, the mountings 14 can be injection-molded together with the tank container 3 in a single manufacturing step.

[0029] In addition, mounting points 22 can be arranged on the tank container 3, via which fixing into a housing, for example a charging device 21, is possible.

[0030] Additionally or alternatively, the tank cap 4 can also be manufactured as a plastic injection-molded part, which allows for a comparatively simple and at the same time extremely precise production of the individual connection points 8. The tank container 3 can also have a level indicator 16, which is implemented, for example, by an area made of transparent plastic together with a scale. Furthermore, a connection point 8' for a filling / draining hose 17 can be arranged on the tank container 3. In addition, molded-on connection nozzles 18 for coolant can also be provided. The connection nozzles 18 can be made of the same plastic as the tank container 3, although it is of course also conceivable that the connection nozzles 18 or the connection points 8, 8' have metallic inserts, via which a particularly reliable connection, for example of a pressure relief valve 10, can be made.generally possible from sensor devices 9 and / or coolant lines 19.

[0031] If one considers the Fig. Figures 3-7 show that the pump module 2 according to the invention comprises at least one coolant pump 5 and a heating device 6 for heating the coolant, as well as a control device 20, which is fixed to the tank 3 or to the tank cap 4 of the coolant tank 1. The control device 20 is connected to at least one of the following components: at least one coolant pump 5, a sensor device 9, a heating device 6, and, for example, a level indicator, provided that this is not purely optical but transmits an electronic signal. The control device 20 may also have an input interface through which it can receive signals from a charging station (not shown).

[0032] Furthermore, the control unit 20 can be designed to independently control the functions and performance of the pump module 2.

[0033] A major advantage of the pump module 2 according to the invention is its extreme flexibility in terms of scalability, achieved through the use of identical components. For example, a second coolant pump 5 can be installed to increase performance. This allows for the relatively simple implementation of larger flow rates. However, the greatest advantage of the pump module 2 according to the invention, which can be installed, for example, in a stationary charging device, such as a charging station for electric or hybrid vehicles, lies in the fact that the tank 3, designed as a load-bearing component, and the tank cap 4, designed as a functional element, enable a significant reduction in installation space requirements.

[0034] The control unit 20 processes the data transmitted by the sensor unit 9 or the electrical connections 13 and uses this data to determine, for example, the current operating state, in particular a cold start mode, normal operation, a boost mode, or an emergency running mode. Furthermore, the control unit 20 can regulate the speed and thus also the power of at least one coolant pump 5 and an unspecified fan to stored target values, so that a coolant supply temperature can be regulated depending on the current state of charge and thus also depending on the current charging power. A temperature sensor 11 also allows conclusions to be drawn about the viscosity of the coolant and thus, for example, about the coolant pressure, so that this can also be regulated accordingly.

[0035] Furthermore, the control unit 20 can detect potential malfunctions or errors, such as overtemperature or pressure loss due to a leak, as well as a defective coolant pump 5. The control unit 20 can be configured to transmit an error signal to an external charging station upon detection of such a malfunction or error, whereupon the charging station ceases charging. The control unit 20 can also receive additional operationally relevant input signals from the charging station, which can, for example, activate an operating state, special time modes (night mode / silent mode), or a safety circuit.

[0036] All in all, a significant reduction in installation space can be achieved with the coolant tank 1 and the pump module 2 according to the invention, which is particularly advantageous for charging devices 21 with only limited installation space available. Reference symbol list 1 coolant tank 2 Pump module 3 tank containers 4 fuel tank caps 5 Coolant pump 6 Heating system 7 frames 8 Junction 9 Sensor setup 10 Pressure relief valve 11 Temperature sensor 12. Bleed screw 13 electrical connections 14th entry 15 hose clamps 16 Level indicator 17 Filling / draining hose 18 connection spigots 19 coolant lines 19 is possible. 20 Control unit 21 Charging equipment 22 Recording point

Claims

[1] Coolant tank (1) for a pump module (2) with a tank container (3) and a tank lid (4) covering it, characterized by , - that the tank (3) is designed as a supporting component for at least one coolant pump (5), - that the tank cap (4) is designed as a functional element and has at least one connection point (8) for a sensor device (9). [2] Coolant tank (1) according to claim 1, characterized by that the sensor device (9) includes a pressure sensor and / or a temperature sensor (11). [3] Coolant tank (1) according to claim 1 or 2, characterized by that the tank (3) has at least one receptacle (14) for the coolant pump (5). [4] Coolant tank (1) according to claim 3, characterized by , that at least one receptacle (14) is designed as a C-shaped receptacle for clipping in or at least partially enclosing an associated coolant pump (5). [5] Coolant tank (1) according to claim 3 or 4, characterized by , that at least one receptacle (14) is formed integrally with the tank container (3). [6] Coolant tank (1) according to any one of the preceding claims, characterized by that the tank container (3) and / or the tank lid (4) are designed as a plastic injection molded part or an aluminum casting part. [7] Coolant tank (1) according to any one of the preceding claims, characterized by , that the tank (3) has a level indicator (16) and / or molded connection ports (18) for coolant. [8] Pump module (2) with a coolant tank (1) according to one of the preceding claims and with at least one coolant pump (5) fixed to the tank container (3) of the coolant tank (1). [9] Pump module (2) according to claim 8, characterized by, that a sensor device (9), in particular a temperature sensor (11) or a pressure sensor, is arranged at at least one connection point (8) on the tank lid (4). [10] Pump module (2) according to claim 8 or 9, characterized by , that a heating device (6) for heating coolant is arranged on the tank container (3). [11] Pump module (2) according to any one of claims 8 to 10, characterized by , that the pump module (2) has a control device (20) which is fixed to the tank container (3) or to the tank lid (4) of the coolant tank (1). [12] Charging device (21) with a pump module (2) according to claim 11, wherein the control device (20) has an input interface through which it can receive signals from sensors.

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