INTEGRATED COOLANT MODULE SYSTEM

Abstract

An integrated coolant module (ICM) system comprises a module with a body. Several flow channels are integrally formed with the body, including a first flow channel, a second flow channel, and a third flow channel. Several flow connectors, each with individual connectors, are attached to individual flow channels. The first flow channel's multiple flow connectors include a first flow connector, a second flow connector, a third flow connector, and a fourth flow connector. The first flow channel provides fluid connectivity between any two or all of the first, second, third, and fourth flow connectors.

Description

INTRODUCTION

[0001] The present invention relates to modules for use in fluid distribution in vehicles and in particular to an integrated coolant module system.

[0002] For general background information, reference is made in advance to the documents DE 10 2021 113 817 A1, DE 10 2021 102 022 A1, DE 10 2013 016 295 A1, DE 10 2024 119 903 A1, CN 1 16 461 285 A, CN 1 17 168 207 A, CN 220 456 458 U, CN 1 18 144 594 A and WO 2024 / 151 923 A1.

[0003] In vehicles, including battery-powered electric vehicles, an integrated coolant module (ICM) defines a system that distributes a fluid, such as coolant, to dissipate heat from vehicle systems, including battery systems, and distribute that heat to heat-dissipating components, including radiators. In a system without an ICM, all thermal components are distributed throughout the compartment under the hood. This results in a complex and costly piping configuration. Due to packaging, flexibility, and sizing requirements, it is typically difficult to incorporate a common coolant distribution solution across multiple vehicle designs. With current module designs, when an ICM solution is required, the solution is vehicle-specific, increasing vehicle complexity and reducing alternatives to using common, cross-platform components.

[0004] While current systems and procedures that provide coolant via an ICM fulfill their intended purpose, there is a need for a new and improved system and procedure that enables the use of ICM in several different vehicle designs. SUMMARY

[0005] According to the invention, an integrated coolant module system (ICM system) is presented, characterized by the features of claim 1 and comprising a module with a body. Several flow channels of the body comprise a first flow channel, a second flow channel, and a third flow channel. Several flow connectors have individual flow connectors attached to individual flow channels. The several flow connectors of the first flow channel comprise a first flow connector, a second flow connector, a third flow connector, and a fourth flow connector. The first flow channel provides a fluid connection between at least two of the first flow connector, the second flow connector, the third flow connector, and the fourth flow connector.

[0006] In another aspect of the present invention, a coolant pump arrangement has several pump flow ports, wherein one of the several flow ports is connected to one of the several flow connectors.

[0007] In another aspect of the present invention, the coolant pump arrangement comprises a pump body defining a housing that accommodates a coolant pump, wherein the coolant pump provides a flow distribution of the coolant via multiple pump flow ports.

[0008] In another aspect of the present invention, the multiple pump flow ports comprise an outlet flow port, a first inlet flow port, a second inlet flow port oriented substantially at 90 degrees to the first inlet flow port, and a third inlet flow port oriented substantially at 90 degrees to the second inlet flow port.

[0009] In another aspect of the present invention, the coolant pump arrangement defines a first coolant pump arrangement in which one of the first inlet flow port, the second inlet flow port and the third inlet flow port is installed on any of the flow connectors of one of the multiple flow channels of the module.

[0010] In another aspect of the present invention, the coolant pump arrangement defines a first coolant pump arrangement in which the third inlet flow port is welded to the second flow connector and the first inlet flow port and the second inlet flow port are blocked.

[0011] In another aspect of the present invention, a modular system comprises a second coolant pump arrangement installed on a different flow channel of the module than the first coolant pump arrangement.

[0012] In another aspect of the present invention, the multiple flow connectors of the second flow channel comprise a fifth flow connector, a sixth flow connector, a seventh flow connector and an eighth flow connector.

[0013] In another aspect of the present invention, the multiple flow connectors of the third flow channel comprise a ninth flow connector, a tenth flow connector, an eleventh flow connector and a twelfth flow connector.

[0014] In another aspect of the present invention, the cooling system distributes the coolant via the module to a coolant supply system of a vehicle and thus to a vehicle battery system.

[0015] Furthermore, a coolant module system integrated into a vehicle is described, comprising a module with a body that distributes a coolant from a cooling system. Several flow channels of the body have individual flow channels that are fluidically separated from the other flow channels and include a first flow channel, a second flow channel, and a third flow channel.Several flow connectors comprise: a first flow connector, a second flow connector, a third flow connector, and a fourth flow connector of the first flow channel, each defining four fluid ports of the first flow channel; a fifth flow connector, a sixth flow connector, a seventh flow connector, and an eighth flow connector of the second flow channel, each defining four fluid ports of the second flow channel; a ninth flow connector, a tenth flow connector, an eleventh flow connector, and a twelfth flow connector of the third flow channel, each defining four fluid ports of the third flow channel.A first coolant pump arrangement comprises several pump flow ports, wherein one of the several pump flow ports is connected to one of the flow connectors of the first flow channel, the second flow channel and the third flow channel to generate a coolant flow through one of the first flow channel, the second flow channel and the third flow channel.

[0016] In another aspect of the present invention, the first flow channel provides a fluid connection between at least two of the first flow connector, the second flow connector, the third flow connector and the fourth flow connector.

[0017] In another aspect of the present invention, a second coolant pump arrangement has several second coolant pump flow ports, wherein one of the several second coolant pump flow ports is connected to one of the flow connectors of a different first flow channel, second flow channel and third flow channel than the first coolant pump arrangement.

[0018] In another aspect of the present invention, a flow adapter is defined as a plastic-welded adapter for a fixed connection with one of the flow connectors.

[0019] In another aspect of the present invention, the flow adapter is defined as a angular adapter, a transition adapter and a plug adapter.

[0020] In another aspect of the present invention, the body is a metal material produced using an additive manufacturing process.

[0021] In another aspect of the present invention, the body is a polymer material that is produced using a shaping process and an additive manufacturing process.

[0022] Furthermore, a method for distributing vehicle coolant via an integrated coolant module (ICM) system is described, the method comprising: forming a module with a body; integrally forming multiple flow channels in the body, comprising a first flow channel, a second flow channel, and a third flow channel; attaching individual of several flow connectors to individual of the first flow channel, the second flow channel, and the third flow channel, wherein the several flow connectors of the first flow channel comprise a first flow connector, a second flow connector, a third flow connector, and a fourth flow connector; providing fluid communication between any two or all of the first flow connector, the second flow connector, the third flow connector, and the fourth flow connector via the first flow channel;and connecting one of several pump flow ports of a first coolant pump arrangement to one of the several flow connectors of the first flow channel, the second flow channel, or the third flow channel to produce a coolant flow through one of the first flow channel, the second flow channel, and the third flow channel.

[0023] In another aspect of the present invention, the method further comprises connecting a second coolant pump arrangement with multiple pump flow ports to one of the flow connectors of a flow channel other than the first flow channel, the second flow channel and the third flow channel to which the first coolant pump arrangement is connected.

[0024] In another aspect of the present invention, the method further comprises collecting a coolant which is conveyed from the first coolant pump arrangement and the second coolant pump arrangement via a coolant return system of a vehicle to a heat exchanger which defines a radiator.

[0025] Further areas of application will become apparent from the description given herein. It is understood that the description and the specific examples serve only for illustrative purposes. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The drawings described herein are for illustrative purposes only. Fig. Figure 1 is a perspective front view from the left of a vehicle with an integrated coolant module (ICM) system according to an exemplary aspect; Fig. Figure 2 is a top view of an exemplary module of the system of Fig. 1; Fig. Figure 3 is a perspective top view of the module of Fig. 2, which furthermore represents exemplary adapters for the fluid system connection; Fig. Figure 4 is a perspective top view of exemplary adapters for the module of Fig. 2; Fig. Figure 5 is a perspective front view of a coolant pump assembly suitable for installation in the module of Fig. 2; Fig. Figure 6 is a top view of a first module system with two coolant pump arrangements of Fig. 5; Fig. Figure 7 is a top view of a second module system with two coolant pump assemblies of Fig. 5; and Fig. Figure 8 is a top view of a third module system with two coolant pump assemblies of Fig. 5. DETAILED DESCRIPTION

[0027] The following description is merely an example.

[0028] With reference to Fig. 1. An integrated coolant module system (ICM system) 10 is provided for a vehicle 12, which may include a battery-electric vehicle, a hybrid-electric vehicle, and a gasoline- or diesel-powered vehicle. A coolant system 14 is provided for distributing a coolant, such as water or a water-antifreeze mixture, via a module 16 of the present invention. According to several aspects, the coolant system 14 can distribute the coolant via the module 16 to a coolant supply system 18 and thereby to vehicle systems, which include a vehicle battery system 20 requiring cooling, and can return all the coolant via a coolant return system 22 to a heat exchanger 24, such as a radiator.

[0029] With reference to Fig. 2 and again on Fig. Module 16 comprises a body 26, which can be made of a polymer material, such as a polyamide, or a metal, and can be manufactured by a molding process or an additive manufacturing process. According to several aspects, Module 16 includes multiple flow channels, including a first flow channel 28, which provides a first flow connector 30, a second flow connector 32, a third flow connector 34, and a fourth flow connector 36. The first flow channel 28 provides a fluid connection between any two or all of the first flow connector 30, the second flow connector 32, the third flow connector 34, and the fourth flow connector 36.

[0030] Module 16 further includes additional flow channels, including a second flow channel 38 with a fifth flow connector 40, a sixth flow connector 42, a seventh flow connector 44, and an eighth flow connector 46. The second flow channel 38 provides a fluid connection between any two or all of the fifth flow connector 40, the sixth flow connector 42, the seventh flow connector 44, and the eighth flow connector 46. An exemplary flow adapter 48 is shown installed in the eighth flow connector 46, which can provide a fluid flow connection to other components, lines, or flow fittings, which are shown and described in more detail below. Fig. 4 to 8.

[0031] Module 16 further comprises an additional flow channel, a third flow channel 50, with a ninth flow connector 52, a tenth flow connector 54, an eleventh flow connector 56, and a twelfth flow connector 58. The third flow channel 50 provides a fluid connection between any two or all of the ninth flow connector 52, the tenth flow connector 54, the eleventh flow connector 56, and the twelfth flow connector 58. The fluid connection is provided via individual flow channels 60 from the first flow channel 28, the second flow channel 38, and the third flow channel 50 to individual flow connectors via at least one fluid connection channel. For example, a fluid connection channel 60 provides a fluid connection from the third flow channel 50 to the tenth flow connector 54.

[0032] Individual components of the first flow channel 28, the second flow channel 38, and the third flow channel 50 are not connected to any other component of the first flow channel 28, the second flow channel 38, or the third flow channel 50. Therefore, no fluid flow is provided between any two or more components of the first flow channel 28, the second flow channel 38, and the third flow channel 50. This allows for individually directed flow to vehicle systems using independently provided flow components, including various flow pumps, which are shown and described in relation to Fig. 6, Fig. 7 and Fig. 8.

[0033] With reference to Fig. 3 and again on Fig. 1 and Fig. 2. The module can include 16 adapters to accommodate mechanically connected or plastic-welded fittings. In the example shown, the seventh flow connector 44 can have a female adapter 62 to accommodate a male connector, which is shown and described in more detail with respect to Fig. 4. Additionally, a male adapter 64 is provided for the twelfth flow connector 58 to accommodate a female connector, which is shown and described in more detail with regard to Fig. 4.

[0034] With reference to Fig. 4 and again on Fig. 1 to 3 include examples of adapters for use on module 16, the flow adapter 48, which is shown and described in relation to Fig. 2, wherein a plastic-welded adapter is defined for a fixed connection with one of the flow connectors, such as the first flow connector 30, the second flow connector 32, the third flow connector 34 and the fourth flow connector 36, which are described with respect to Fig. 2. An angle adapter 66 comprises a plastic-welded flange 66a, a male adapter section 66b, and an angled section 66c. A transition adapter 68 comprises a female pipe connector 68a and a male adapter section 68b. A push-fit adapter 70 comprises a plastic-welded flange 70a, for example, for plastic welding to one of the flow connectors, such as the first flow connector 30, the second flow connector 32, the third flow connector 34, and the fourth flow connector 36, which are described with respect to Fig. 2. The plug adapter further comprises a male plug section 70 for insertion into a connection opening of one of the flow connectors, such as the first flow connector 30, the second flow connector 32, the third flow connector 34 and the fourth flow connector 36, which are described with regard to Fig. 2, and, if installed, serves to permanently close the connection opening.

[0035] With reference to Fig. 5 and again on Fig. Figures 1 to 4 describe a coolant pump assembly 72 for installation on any of the flow connectors of the module 16. A pump body 74 defines a housing that accommodates flow components of the coolant pump 76, such as an impeller (not shown), and provides the flow distribution of the coolant via multiple flow ports, including an outlet flow port 78, a first inlet flow port 80, a second inlet flow port 82 oriented substantially at 90 degrees from the first inlet flow port 80, and a third inlet flow port 84 oriented substantially at 90 degrees from the second inlet flow port 82. The body 74 also provides a mounting surface 85 for detachably attaching the coolant pump 76 to the body 74 of the coolant pump assembly 72.The alignment of the multiple flow ports makes it possible to align the coolant pump assembly 72 in 90-degree increments on the module 16.

[0036] With reference to Fig. 6 and again on Fig. 1 to 5, a first module system 86 comprises a module 16 and provides a first coolant pump assembly 72a and a second coolant pump assembly 72b. The first coolant pump assembly 72a is mounted such that the third inlet flow port 84 is plastic-welded to the second flow connector 32 and the first inlet flow port 80 and the second inlet flow port 82 are blocked. The coolant flow can enter the first flow connector 30 in an inlet flow direction 88 and is discharged from the outlet flow port 78 of the first coolant pump assembly 72a in an outlet flow direction 90.

[0037] The second coolant pump assembly 72b is mounted such that the second inlet flow port 82 is plastic-welded to the tenth flow connector 54, and the first inlet flow port 80 and the third inlet flow port 84 are blocked. The coolant flow can enter the ninth flow connector 52 in an inlet flow direction 92 and is discharged from the outlet flow port 78 of the second coolant pump assembly 72b in an outlet flow direction 94. It should be noted that, in this respect, the outlet flow direction 94 is oriented approximately 90 degrees with respect to the outlet flow direction 90.

[0038] With reference to Fig. 7 and again on Fig. In sections 1 to 6, a second module assembly 96 is modified compared to the first module assembly 86 and is suitable for installation on at least one other flow connector of module 16. A first coolant pump assembly 72c is mounted such that the second inlet flow port 82 is plastic-welded to the third flow connector 34, and the first inlet flow port 80 and the third inlet flow port 84 are blocked. The coolant flow can enter the second flow connector 32 in an inlet flow direction 98 and is discharged from the outlet flow port 78 of the first coolant pump assembly 72c in an outlet flow direction 100.

[0039] A second coolant pump assembly 72d is mounted such that the second inlet flow port 82 is plastic-welded to the tenth flow connector 54, and the first inlet flow port 80 and the third inlet flow port 84 are blocked. The coolant flow can enter the ninth flow connector 52 in an inlet flow direction 102 and is discharged from the outlet flow port 78 of the second coolant pump assembly 72d in an outlet flow direction 104. It should be noted that in this respect, the outlet flow direction 104 is opposite and thus oriented approximately 180 degrees with respect to the outlet flow direction 100.

[0040] With reference to Fig. 8 and again on Fig.1 to 7, a third module arrangement 106 is modified compared to the first module arrangement 86 and the second module arrangement 96 and is suitable for installation on at least one other flow connector of module 16. A first coolant pump arrangement 72e is mounted such that the first inlet flow port 80 is plastic-welded to the third flow connector 34 and the second inlet flow port 82 and the third inlet flow port 84 are blocked. The coolant flow can enter the second flow connector 32 in an inlet flow direction 108 and is discharged from the outlet flow port 78 of the first coolant pump arrangement 72e in an outlet flow direction 110.

[0041] A second coolant pump assembly 72f is mounted such that the first inlet flow port 80 is plastic-welded to the eleventh flow connector 56, and the second inlet flow port 82 and the third inlet flow port 84 are blocked. The coolant flow can enter the ninth flow connector 52 in an inlet flow direction 112 and is discharged from the outlet flow port 78 of the second coolant pump assembly 72f in an outlet flow direction 114. It should be noted that in this respect, the outlet flow direction 114 is opposite and thus oriented at approximately 180 degrees with respect to the outlet flow direction 110.

[0042] The ICM system 10 of the present invention centralizes the coolant hardware into a single module, thereby eliminating the need to expand coolant lines. The ICM system 10 uses a common ICM background or module 16 to reduce the number of components and provide efficient packaging. The ICM system 10 of the present invention provides at least three (3) different positions and orientations for the installation of coolant pump modules. In combination with the connectors and end caps, the ICM system 10 provides at least twenty-four (24) possible positions for components from a single module 16 without requiring special tooling for different vehicle platforms or coolant mechanization.

[0043] The ICM system 10 of the present invention, compared to the current concept of integrated coolant modules, provides packaging flexibility and a reduction in tooling complexity, which includes a reduction in tooling distribution and a reduction in parts distribution across vehicles. Packaging flexibility is improved by the ability to exchange connection connections and positions as needed to enable different types of connection mechanization concepts on different vehicle platforms. The reduction in complexity is also provided in the vehicle's bill of materials (BOM); reduction in BOM management: components, suppliers, and parts in vehicle assembly plants.

[0044] An ICM system 10 of the present invention has several advantages. These include: a methodology for interconnected coolant modules to position / align ports, six-way valves, coolant pumps, or other coolant hardware at different locations on a single module, providing flexibility to achieve various packaging solutions using common core modules. Designers and vehicle architects can adapt the present ICM concept to different vehicle platforms. The ICM module of the present invention uses current plastic welding technologies to isolate or open channels in a main circuit board, thereby creating additional coolant branches available for mechanization if required.

Claims

[1] Integrated coolant module system (ICM system) (10), comprising: a module (16) with a body (26); several flow channels (28, 38, 50) formed integrally with the body (26), including a first flow channel (28), a second flow channel (38) and a third flow channel (50); several flow connectors with individual of the several flow connectors attached to individual of the several flow channels (28, 38, 50); wherein the multiple flow connectors of the first flow channel (28) comprise a first flow connector (30), a second flow connector (32), a third flow connector (34) and a fourth flow connector (36); and the first flow channel (28) provides a fluid connection between at least two of the first flow connector (30), the second flow connector (32), the third flow connector (34) and the fourth flow connector (36). [2] Integrated coolant module system (ICM system) (10) according to claim 1, further comprising a coolant pump arrangement with multiple pump flow ports, wherein one of the multiple pump flow ports is connected to one of the multiple flow connectors. [3] Integrated coolant module system (ICM system) (10) according to claim 2, wherein the coolant pump arrangement comprises a pump body (74) defining a housing that accommodates a coolant pump (76), wherein the coolant pump (76) provides a flow distribution of the coolant via multiple pump flow ports. [4] Integrated coolant module system (ICM system) (10) according to claim 3, wherein the multiple pump flow ports comprise an outlet flow port (78), a first inlet flow port (80), a second inlet flow port (82) oriented substantially at 90 degrees to the first inlet flow port (80), and a third inlet flow port (84) oriented substantially at 90 degrees to the second inlet flow port (82). [5] Integrated coolant module system (ICM system) (10) according to claim 4, wherein the coolant pump arrangement defines a first coolant pump arrangement (72e) with one of the first inlet flow port (80), the second inlet flow port (82) and the third inlet flow port (84), which is installed on any of the flow connectors of one of the multiple flow channels (28, 38, 50) of the module (16). [6] Integrated coolant module system (ICM system) (10) according to claim 4, wherein the coolant pump arrangement defines a first coolant pump arrangement (72e) with a third inlet flow port (84) which is plastic welded to the second flow connector (32) and wherein the first inlet flow port (80) and the second inlet flow port (82) are blocked. [7] Integrated coolant module system (ICM system) (10) according to claim 5, further comprising a module system (86) with a second coolant pump arrangement (72f) installed on a different flow channel (28, 38, 50) of the module (16) than the first coolant pump arrangement (72e). [8] Integrated coolant module system (ICM system) (10) according to claim 1, wherein the multiple flow connectors of the second flow channel (38) comprise a fifth flow connector (40), a sixth flow connector (42), a seventh flow connector (44) and an eighth flow connector (46). [9] Integrated coolant module system (ICM system) (10) according to claim 8, wherein the multiple flow connectors of the third flow channel (50) comprise a ninth flow connector (52), a tenth flow connector (54), an eleventh flow connector (56) and a twelfth flow connector (58). [10] Integrated coolant module system (ICM system) (10) according to claim 1, comprising a coolant supply system (18) of a vehicle (12) which provides the supply of a coolant via one of the multiple flow channels (28, 38, 50).

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