Thermal management module and vehicle comprising at least one such thermal management module

Abstract

The invention relates to a thermal management module (1) for managing mass flows of a temperature-control medium in at least one temperature-control circuit of a vehicle, wherein the thermal management module (1) comprises at least one module housing (10), at least one fluid connection device (50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64), and at least one fluid path in the interior of the module housing (10). According to the invention, the module housing (10) comprises at least one supporting structural component (2) and at least one cover element (3). The at least one supporting structural component (2) and the at least one cover element (3) are connected together or can be connected together and form the at least one fluid channel (4, 4a, 4b, 4c, 4d, 4e) between each other as a fluid path.

Description

[0001] Thermal management module and vehicle with at least one such

[0002] The invention relates to a thermal management module for managing mass flows of a temperature control medium in at least one temperature control circuit of a vehicle, wherein the thermal management module comprises at least one module housing, at least one fluid connection device and at least one fluid path in the interior of the module housing, as well as a vehicle with at least one temperature control circuit for temperature control of vehicle components, in particular at least one battery and at least one electronic component, wherein at least one thermal management module is provided for managing mass flows of a temperature control medium in the at least one temperature control circuit.

[0003] In today's vehicles, especially electric vehicles and hybrid vehicles, more and more electronically controlled components, such as electrically adjustable control valves, electrically adjustable pumps, a multitude of sensors, etc., are arranged along the vehicle's fluid circuits or temperature control circuits, such as cooling circuits. This results in the advantage of demand-based and driving-condition-optimized thermal management, which supports both driving comfort and vehicle range optimization. The temperature control medium used in each case is carried in a closed system of a vehicle's temperature control circuit.Such a temperature control circuit comprises at least a first sub-circuit, which serves to control the temperature of a traction battery, at least a second sub-circuit, which serves to control the temperature of at least one electronic component, and at least a third sub-circuit, which comprises a heat exchanger, which serves to absorb heat from the ambient air of the vehicle and to release heat to it and through which the temperature control medium also flows, so that heat can be transferred through the heat exchanger into the temperature control medium and from there to the ambient air. The climate comfort for the interior or cabin of a vehicle can also be regulated via the third sub-circuit. Each of the sub-circuits has a supply line and a return line.To manage mass flows of a temperature control medium in such a temperature control circuit of a vehicle, a thermal management module can be provided which comprises a module housing, some fluid connection devices and a fluid channel inside the module housing.

[0004] For example, DE 10 2020 206 268 A1 discloses a thermal management system for a battery of a motor vehicle, in particular an electric vehicle, a battery-electric vehicle, or a hybrid electric vehicle, which comprises a control unit, a first coolant circuit, and a second coolant circuit. The first coolant circuit has a battery, a chiller, and a first pump, and the second coolant circuit has an auxiliary heater, a heater core, and a second pump. The first and second coolant circuits are thermally or thermally fluidically coupled to one another via a coupling device. The control unit is designed such that the outputs of the first pump and the second pump are regulated to meet the thermal management requirements.This prior art document demonstrates the complexity of such a thermal management system with multiple cooling circuits with a number of components, such as pumps, batteries, auxiliary heaters, etc., wherein the cooling circuits are coupled and nested within each other.

[0005] To solve this problem, DE 10 2021 102 473 A1 proposes a thermal management module for a cooling system for a motor vehicle with an electric drive system, which module has a module housing with a plurality of cooling fluid connections, wherein the cooling fluid connections comprise a first cooling fluid connection, a second cooling fluid connection, and a third cooling fluid connection, and a control valve arranged in the module housing is provided for controlling a fluid flow between the cooling fluid connections. The thermal management module has a first connecting line for conducting cooling fluid, wherein the first connecting line couples the first cooling fluid connection to the second cooling fluid connection in a fluid-communicating manner. An interior space is formed inside the module housing of the thermal management module, in which an control valve designed as a rotary slide valve is arranged.The control valve enables a fluid-communicating connection between the individual cooling fluid connections to be switched on and off. For this purpose, the control valve has valve chambers with valve chamber openings that can be aligned with the corresponding cooling fluid connections, allowing at least two cooling fluid connections to be fluidly connected to one another via a valve chamber. This thermal management module is thus a special valve tailored to a specific application in the form of a 9 / x directional valve for regulating the cooling medium in various branches of the cooling system. It is highly complex and elaborate, and therefore expensive. It comprises the module housing, into which the other aforementioned components are inserted and attached. The complex structure of the thermal management module in the form of a multi-way valve proves to be disadvantageous in itself.It is also relatively error-prone and not versatile or universally applicable.

[0006] The present invention is therefore based on the object of developing a thermal management module for managing mass flows of a temperature control medium in at least one temperature control circuit of a vehicle, wherein the thermal management module comprises at least one module housing, at least one fluid connection device and at least one fluid path in the interior of the module housing, as well as a vehicle with at least one such thermal management module in such a way that any desired number of fluid paths and also fluid paths with different sections and flow-optimized fluid paths can be easily formed in the module housing.

[0007] The object is achieved for a thermal management module according to the preamble of claim 1 in that the module housing comprises at least one supporting structural component and at least one cover element, wherein the at least one supporting structural component and the at least one cover element are connectable or connected to one another and form the at least one fluid channel as a fluid path between them. The object is also achieved for a vehicle with at least one temperature control circuit for controlling the temperature of vehicle components, in particular at least one battery and at least one electronic component, wherein at least one such thermal management module is provided for managing mass flows of a temperature control medium in the at least one temperature control circuit. Further developments of the invention are defined in the dependent claims.

[0008] This creates a thermal management module for managing mass flows of a temperature control medium in at least one temperature control circuit of a vehicle, in which the module housing comprises at least one load-bearing structural component and at least one cover element. The at least one load-bearing structural component and the at least one cover element are or are connected to one another, in particular bonded, such as by welding. Between these two components of the module housing, i.e. the at least one load-bearing structural component and the at least one cover element, the at least one fluid channel is formed as a fluid path in the interior of the module housing. Therefore, both the at least one load-bearing structural component and the at least one cover element are advantageously designed as shell-shaped hollow shapes.After joining the at least one supporting structural component and the at least one cover element, at least one channel-shaped cavity remains between them, thus forming the at least one fluid channel. The at least one fluid channel can be flowed through by the temperature control medium. It serves to fluidically connect at least one component for conveying the temperature control medium and at least one component for mass flow control of the temperature control medium, which are arranged on and / or within the supporting structural component or engaging in the latter or the module housing and the fluid channels formed therein, and from these to fluid connection devices provided on the thermal management module, to which media lines can be connected.

[0009] In order to provide an application-specific, optimal shape for the at least one load-bearing structural component and / or the at least one cover element and accordingly also for the at least one fluid channel formed between them, the at least one load-bearing structural component and / or the at least one cover element can be designed, for example, as injection-molded parts, deep-drawn parts or die-cast parts, in particular plastic injection-molded parts. Especially when plastic injection-molded parts are provided, the at least one load-bearing structural component and the at least one cover element can advantageously be or become materially connected to one another by laser welding. Of course, another type of materially bonded connection can also be provided which enables a media-tight connection of the at least one load-bearing structural component and the at least one cover element.

[0010] The at least one load-bearing structural component is advantageously designed such that at least one component for conveying the temperature control medium and at least one component for mass flow control can be arranged thereon or is arranged thereon or is integrated into it, in particular at least two components for conveying the temperature control medium and at least one component for mass flow control. Managing mass flows means that fluid medium mass flows within the thermal management module are conveyed, in particular pumped, by the at least one component for conveying the temperature control medium, and are accordingly metered, adjusted, or regulated by the at least one component for mass flow control and supplied to the respective fluid connection devices of the thermal management module, so that they can flow accordingly for temperature control in the respective lines of the temperature control circuit or its sub-circuits, in which vehicle components to be temperature controlled are arranged.Vehicle components to be tempered include batteries, such as a traction battery, and electronic components; heat exchangers and / or temperature control devices or heat sources and / or heat sinks can be arranged in the sub-circuits.

[0011] The at least one supporting structural component is advantageously designed such that at least one component for conveying the temperature control medium and at least one component for mass flow control can be arranged thereon or are arranged thereon or are integrated into it, in particular at least two components for conveying the temperature control medium and at least one component for mass flow control. For arranging the at least one component for conveying the temperature control medium and the at least one component for mass flow control, the shell-shaped supporting structural component is provided, for example, with one or more receiving sections on which these components can be optimally accommodated.In particular, the at least one supporting structural component can have at least one through-opening through which a drive shaft or axle or other sections of the components can engage in the at least one fluid channel inside the module housing created by the materially bonded connection of the at least one supporting structural component and the at least one cover element. The components can extend through the wall of the supporting structural component in order to protrude into or engage in the at least one fluid channel and to be able to regulate the mass flow of the temperature control medium flowing through there. Further advantageously, the at least one supporting structural component orThe thermal management module is or will be designed such that the at least one component for conveying the temperature control medium, such as a pumping device, and the at least one component for mass flow control, such as a valve, are or can be installed from the same side of the at least one supporting structural component or the thermal management module. Equipping the supporting structural component is thus possible from one side, which leads to a significant simplification of the assembly of the components on the supporting structural component due to good accessibility of the receiving sections of the supporting structural component.

[0012] The at least one cover element can be formed as a single piece or in multiple parts. This makes it possible to create multiple separate fluid channels within the module housing. This is particularly possible by providing multiple separate cover elements that are connected to the supporting structural component at designated, separate locations, thus forming fluid channels between the supporting structural component and the cover elements.

[0013] Furthermore, a single cover element can be provided and shaped such that it has sections designed or shaped to form fluid channels between the supporting structural component and the cover element, as well as flat connecting sections or at least sections not shaped to form fluid channels, which are arranged between the shaped sections of the cover element and connect them to one another to form the one-piece cover element. By providing a one-piece cover element, the rigidity of the module housing can be increased compared to providing a number of separate cover elements that are connected to the supporting structural component.

[0014] Thus, a single-piece, segmented, or multi-piece cover element can be provided and connected to the supporting structural component. To withstand high pressure loads, a small-area design of the cover element is suitable, either by providing a multi-piece cover element or by providing a cover element with shaped sections and connecting sections arranged between them.

[0015] The connection region, in which the at least one cover element and the at least one load-bearing structural component are connected to one another in a materially bonded manner, in particular by welding, such as laser welding, advantageously lies in one plane. The cover element and the load-bearing structural component are inherently rigid, and the cover element in particular also has a high surface rigidity. This makes it possible for it to support the weld seam between the cover element and the load-bearing structural component. Thus, due to the surface rigidity of the at least one cover element, especially of a one-piece cover element, the at least one weld seam between the cover element(s) and the load-bearing structural component can be relieved, in particular even when the entire weld seam lies in one plane.If the module housing is subjected to internal pressure in the area of ​​its load-bearing structural component and / or its cover element(s), this can result in tensile stress on the welded joint. With a flat cover element, shear stress would occur due to the bulging of the cover element. The internal pressure is applied when the temperature control medium is under pressure and flows through the at least one fluid channel formed between the load-bearing structural component and the cover element(s) inside the module housing of the thermal management module. If the cover element is designed as a single piece, the entire welding zone orThe weld seam, as already mentioned, is in one plane, which simplifies the manufacturing process of the thermal management module, since only one component, in the form of the cover element, is welded to a supporting structural component in one plane, without increasing the fill volume or creating disadvantages due to unfavorable flow guidance of the temperature control medium in the at least one fluid channel inside the module housing of the thermal management module. Increasing the fill volume would lead to weight disadvantages in the filled state of the thermal management system or its fluid channel(s).

[0016] In particular, the at least one cover element, but also the at least one supporting structural component, can further advantageously be designed as a two-component part. For example, the region of the at least one cover element and the at least one supporting structural component that forms or encompasses the weld seam between the two can be designed to be more stable, while another region can be designed to be more elastic or flexible. A particularly stable welded connection or weld seam between the cover element(s) and the supporting structural component can advantageously be created if the region of the weld seam connecting the cover element(s) and the supporting structural component is made of a stable material.

[0017] Component deformations can be accommodated by providing structurally more flexible areas, such as the grid-shaped areas, to prevent damage to the thermal management module or its supporting structural component and cover element(s), especially in critical load cases such as impact loads. It is also possible to accommodate component deformations by using more flexible or elastic material in functionally critical areas or areas away from the weld seam.

[0018] If the cover element is constructed in multiple parts, it can be connected to the at least one supporting structural component in more than one plane. With a multi-part cover element, welding of the supporting structural component and the multi-part cover element(s) is thus possible in multiple planes. However, this proves to be complex and is therefore less preferred. In principle, even with a multi-part cover element(s), welding of the supporting structural component to the multi-part cover element(s) is possible in one plane.

[0019] The supporting structural component of the thermal management module is advantageously designed to be substantially flat, meaning that its vertical extension is significantly less than its planar extension. In the areas where fluid connection devices are formed or configured in the direction of its vertical extension, the height of the supporting structural component is naturally greater than in the areas of the supporting structural component provided in between. By providing a significantly smaller vertical extension compared to the planar extension, a space-saving design of the supporting structural component in the direction of its vertical extension is possible, while at the same time, a stable design is possible.

[0020] The at least one cover element can further advantageously be at least partially trough-shaped to form different flow cross-sections of the at least one fluid channel between the at least one cover element and the at least one supporting structural component. Such a trough shape of the cover element forms a first half-shell or partial shell of the fluid channel cross-section, and the hollow shape or shell shape of the supporting structural component forms a second half-shell or partial shell of the fluid channel cross-section, so that after the cover element and the supporting structural component are joined and connected, the complete fluid channel cross-section is formed between their partial shells or half-shells.

[0021] Further advantageously, the at least one cover element can be shaped differently across its cross-section in multiple dimensions to optimize the flow of the temperature control medium flowing within the at least one fluid channel inside the module housing of the thermal management module. For example, the at least one cover element can have bulged or projecting sections and recessed or trough-shaped sections in the direction of the supporting structural component. As a result, the flow cross-section of the fluid channel formed between the supporting structural component and the cover element can be smaller in the region of the bulged or projecting sections than in the region of the recessed or trough-shaped sections of the cover element.Due to the multi-dimensionally different shaping of the at least one cover element, it is thus possible to give the cover element a shape over its extent such that fluid channels of different shapes and / or dimensions can be created in certain sections between the cover element and the at least one supporting structural component, with correspondingly different flow cross-sections. As a result, the different components arranged on and / or in the supporting structural component, i.e. the at least one component for conveying the temperature control medium, e.g. at least one pump device, and the at least one component for mass flow control, e.g. at least one valve, can also allow highly different mass flows to flow through the fluid channels inside the module housing in the various areas of the thermal management module, depending on the requirements of the respective application.

[0022] Furthermore, one or more sensors can be arranged in the at least one cover element, in particular in the region of the at least one fluid channel or in the at least one fluid channel. For example, one or more sensors can be integrated into the at least one cover element, such as at least one temperature sensor, and can protrude into the flow contours that form the fluid channel together with the formations in the supporting structural component, or can record data there.

[0023] The fluid channels created inside the module housing of the thermal management module are in flow connection with the fluid connection devices, which are also arranged or formed on the module housing. Media lines in the form of hoses and / or pipes can be connected to the fluid connection devices. The temperature control circuit of a vehicle can comprise a number of sub-circuits, in particular at least three sub-circuits, which or their corresponding media lines are or can be connected to the fluid connection devices of the thermal management module. A wide variety of components of the vehicle can be supplied with temperature control medium, such as coolant, via the sub-circuits of the temperature control circuit.To allow flow volumes adapted to subcircuits to flow through the module housing of the thermal management module, the possibility of providing differently shaped and / or dimensioned fluid channels inside the module housing of the thermal management module proves to be very advantageous. To optimize flow, different flow cross-sections can be advantageously provided, through which different volumes of temperature control medium can flow.

[0024] Further advantageously, the at least one fluid connection device can be arranged or formed on the at least one supporting structural component and / or the at least one cover element. Particularly preferably, the at least one fluid connection device is formed on the supporting structural component. In particular, the at least one fluid connection device can extend in the direction of the curvature of the hollow or shell shape of the supporting structural component, i.e. in the direction of the height of the supporting structural component, and / or in the direction of the planar extension thereof, i.e. approximately perpendicular to the extension in the direction of its height. The formation of the fluid connection device(s) in the direction of the curvature of the hollow or shell shape of the supporting structural component advantageously leads to good demoldability of the supporting structural component when it is manufactured using the injection molding process, since demolding is easily possible after opening an injection mold.But it is also possible to demould fluid connection devices arranged in the planar extension of the load-bearing structural component without any problems.

[0025] Particularly when a large number of fluid connection devices are provided closely adjacent to one another or in a confined space on or at the load-bearing structural component, problems can arise during demolding because the underfloor slides of an injection molding tool would collide with the adjacent fluid connection devices when opening to demold the injection-molded load-bearing structural component. This would then result in demolding being impossible or at least not possible without damaging the fluid connection devices. This problem can be solved in that the at least one fluid connection device is or is formed from at least one receiving section formed in the at least one load-bearing structural component and at least one fluid connection section formed in the at least one cover element and insertable or inserted into the at least one receiving section.The fluid connection section, which is formed in at least one cover element, is thus inserted into the receiving section in the supporting structural component and, together with it, forms the fluid connection device. Although installing the fluid connection section in the cover element makes the tooling concept of the cover element more complex, it allows for significant savings in installation space, allowing multiple fluid connection devices to be arranged in a smaller space.

[0026] Further advantageously, at least one sealing element can be provided for fluidically sealing the connection between the receiving section and the fluid connection section and can be arranged or positioned between them. Since the fluid connection section on the cover element is inserted into the receiving section on the supporting structural component, sealing this connection by providing the at least one sealing element proves to be particularly advantageous.

[0027] The at least one load-bearing structural component can be at least partially lattice-shaped. In particular, in the lattice-shaped region(s) of the at least one load-bearing structural component, no cover element is advantageously provided, or the at least one cover element extends only outside the at least one lattice-shaped region of the load-bearing structural component. The at least one lattice-shaped region formed only in the load-bearing structural component enables thermal decoupling of individual regions of the load-bearing structural component from other adjacent regions, since little or hardly any heat is / can be transferred via the respective lattice-shaped section of the load-bearing structural component. Other regions of the load-bearing structural component can be thermally coupled in a targeted manner, in which case, for example, no lattice-shaped design of the load-bearing structural component is provided in these regions.Known thermal management modules typically feature fully closed plastic injection molding geometries. This results in a relatively large projected surface area relative to the component volume, which inevitably requires injection molding machines capable of producing such large components. Large surfaces result in large machine clamping forces, thus leading to high investment costs and, accordingly, high component costs. In the load-bearing structural component according to the invention, however, regions that do not fulfill fluidic functions can advantageously be formed in a grid-like manner. This also allows the dimensions of a corresponding injection molding machine for producing the thermal management module or its load-bearing structural component to be reduced compared to the prior art.Likewise, the material used in the production of an injection-molded supporting structural component of the thermal management module can be reduced compared to the prior art, and the warpage of the component can also be reduced compared to the large-volume injection molding geometries of the prior art. Since thermal management modules are preferably arranged in the engine compartment of a vehicle, it is also possible to create no or at least fewer siphon areas, so that no accumulation of dirt or splash water occurs through the grid-like areas of the supporting structural component, since dirt and splash water can flow off unhindered through the grid-like areas of the supporting structural component.

[0028] Furthermore, by providing the lattice-shaped regions of the load-bearing structural component, its rigidity can be partially increased or modified in a targeted manner. This makes it possible to specifically reduce mechanical stress, particularly on weld seams provided on or within the load-bearing structural component, such as the weld seams between the at least one load-bearing structural component and the at least one cover element. The lattice-shaped regions of the load-bearing structural component allow a certain degree of elasticity and thus component deformation to be specifically permitted in non-functionally critical regions of the load-bearing structural component remote from the weld seam. This makes it possible for limit load cases, such as impact loading on rough roads or a vehicle driving over a curb, to prevent damage to the functional regions of the load-bearing structural component of the thermal management module, thus ensuring that these remain undamaged.The original shape of the lattice-shaped areas of the load-bearing structural component can change under the influence of load, so that, for example, an original square can become a rhombus when deformed. The areas, which are preferably specifically optimized for stiffness, thus make it possible to design subsections or areas of the load-bearing structural component to be soft and thus keep harmful stresses away from functional areas. In some areas, for example, particularly high stiffness may be required or desirable. Functionally damaging loads can be kept away from the sensitive areas of the load-bearing structural component and thus of the thermal management module, such as weld seams and sealing areas as well as other functional areas in which components, such as at least one pumping device and at least one valve, are or are arranged.

[0029] The supporting structural component can also withstand varying temperature loads very well thanks to the provision of grid-shaped areas. These can move through slight deformation without cracking, thus counteracting damage to the supporting structural component. The grid-shaped areas of the supporting structural component enable an optimized heat balance through the ambient air, so that specific areas of the thermal management module can be specifically surrounded by ambient air in order to absorb heat from it or dissipate heat to the ambient air. The heat exchange or insulation of sub-functional areas of the thermal management module can also be varied by varying the shape of the grid-shaped area(s), i.e. the ratio of ribs to openings in the grid-shaped areas.The supporting structural component, and thus the entire module housing of the thermal management module, can thus be thermally decoupled in certain areas by providing at least one grid-shaped area. The supporting structural component can also be thermally coupled in other areas, particularly those areas that are not separated from one another by a grid-shaped area. The design of the grid-shaped areas, and thus the ratio of ribs to openings that together form the grid-shaped areas, can thus vary the heat exchange and insulation of subfunctional areas of the thermal management module.

[0030] Furthermore, lattice-shaped regions of the load-bearing structural component enable functional areas to be produced in the injection molding process by alternately submerging the injection molding tool halves—in effect, undercut functional areas of the load-bearing structural component—in a simplified manner using an opening and closing movement of the injection mold. This also makes it possible to work with lower pressures compared to the production of large-volume injection molding geometries of the thermal management modules of the prior art. Furthermore, it is possible to ensure sufficient holding pressure during the injection molding process to prevent air bubbles, particularly in the lattice-shaped regions of the load-bearing structural component to be produced. This ensures that no defects remain after shrinkage during the cooling of the injection molding compound, especially not in the lattice-shaped regions of the load-bearing structural component.Furthermore, a more homogeneous material distribution can be provided and less material is required for the production of the thermal management modules according to the invention or of their supporting structural component than in the injection molding geometries of the thermal management modules of the prior art, so that the costs for this can also be kept lower compared to the prior art.

[0031] Furthermore, the load-bearing structural component can advantageously have acoustically decoupled regions within its structure in order to prevent sound waves from being transmitted and also introduced via the thermal management module into a vehicle in which the module is installed. Such acoustic decoupling can be achieved, for example, by targeted stiffness designs that result in a shift in the natural frequencies. The load-bearing structural component can, in particular, have acoustically decoupled regions in the area of ​​its lattice-shaped regions through targeted stiffness designs, so that a shift in the natural frequencies can lead to acoustic decoupling there. Furthermore, damping materials can be incorporated into the lattice-shaped regions of the load-bearing structural component and / or notches can be specifically provided in the lattice-shaped regions of the structural component and / or other measures for acoustic decoupling can be taken.Furthermore, it is possible to provide fastening points or fastening areas for fastening the thermal management module or its load-bearing structural component in a vehicle with damping material in order to create acoustic decoupling there too. For example, screwing can be provided in the area of ​​the fastening points of the load-bearing structural component of the thermal management module in a vehicle, with a damping material such as a foam material being arranged in the area of ​​the screw connection or in the area of ​​the fastening point. This serves to reduce the transmission of structure-borne noise. The thermal management module or its load-bearing structural component can therefore also be partially made of different materials and thus be designed as a two-component component. For acoustic decoupling, as mentioned, foam materials orOther damping materials can be used, or even overmolding with damping material or partial overmolding with damping material. Thus, a wide variety of acoustic decoupling designs can be provided.

[0032] To further explain the invention, exemplary embodiments are described in more detail below with reference to the drawings. These show:

[0033] Figure 1 is a plan view of a first embodiment of a thermal management module according to the invention, Figure 1 a is a first side view of the thermal management module according to Figure 1,

[0034] Figure 1 b shows a second side view of the thermal management module according to Figure 1,

[0035] Figure 1 c is a bottom view of the thermal management module according to Figure 1, thus in plan view of its cover element,

[0036] Figure 2a is a perspective top view of the supporting structural component of the thermal management module according to the invention according to Figure 1,

[0037] Figure 2b is a perspective top view of the cover element according to the invention of the thermal management module according to Figure 1,

[0038] Figure 2c is a perspective bottom view of the cover element according to Figure 2b,

[0039] Figure 2d is a perspective bottom view of the supporting structural component according to Figure 2a,

[0040] Figure 3 is a longitudinal sectional view through a module housing according to the invention with a supporting structural component and cover element of a thermal management module according to the invention in the region of a fluid connection device thereof,

[0041] Figure 4a shows a perspective detailed view of a supporting structural component according to the invention of a thermal management module according to the invention in the region of two adjacent fluid connection devices thereof,

[0042] Figure 4b is a perspective view of the load-bearing structural component rotated by 90° compared to the view in Figure 4a,

[0043] Figure 4c is a longitudinal sectional view of the load-bearing structural component according to Figure 4a, along the line AA of Figure 4b,

[0044] Figure 5a shows a perspective detailed view of a further embodiment of a supporting structural component according to the invention of a thermal management module according to the invention,

[0045] Figure 5b is a perspective view of the load-bearing structural component rotated by 90° compared to the illustration in Figure 5a,

[0046] Figure 5c shows a longitudinal sectional view through the supporting structural component according to Figure 5a, along the line BB of Figure 5b, wherein one of the two fluid connection devices is formed in the supporting structural component, the other fluid connection device is two-part and has a receiving section formed in the supporting structural component and a fluid connection section formed in the cover element and inserted into the receiving section, and

[0047] Figure 6 is a perspective detailed view of an injection molding tool in the area of ​​three underfloor slides during a demolding process, in which one of the underfloor slides collides with the one closely adjacent to it during demolding of one fluid connection device.

[0048] Figures 1 to 2d show a thermal management module 1 having a module housing 10 composed of a supporting structural component 2 and a cover element 3. Both the supporting structural component 2 and the cover element 3 are each formed as hollow shapes or shell-shaped, particularly by injection molding. The respective hollow shape or shell shape can be seen particularly clearly in Figures 2c and 2d. The cover element 3, as can be seen particularly clearly in Figure 2b, has a multi-dimensional, differently shaped surface across its length and width, i.e., length and width, and also across its height, thus in the x-axis, y-axis, and z-axis directions. It has projecting sections, sections that are recessed relative to these sections, and also flat sections. With this multi-dimensional shape, the cover element 3 engages the supporting structural component 2 from its open underside 20.In order to connect the supporting structural component 2 to the cover element 3, in the embodiment shown here the cover element 3 has a substantially flat projecting edge 30.

[0049] This can be seen in particular in the sectional view in Figure 3. As can be seen particularly clearly there, the load-bearing structural component 2 is joined to the edge with the end face 21 of its circumferential shell wall 22. The circumferential shell wall 22 of the load-bearing structural component 2 can be integrally connected in the region of its end face 21 to the projecting circumferential edge 30 of the cover element 3, in particular by welding, such as laser welding. In order to prevent unwanted escape of temperature control medium in the connection area between the load-bearing structural component 2 and the cover element 3, it proves advantageous to provide a material-to-material connection between the two here. Thus, after the material-to-material connection, for example by welding, a circumferential connecting or weld seam 11 can be provided around the module housing 10, as is also indicated in Figure 3.

[0050] As can also be clearly seen in Figure 3, the cover element 3, with its multi-dimensional shape, projects into the interior 23 of the hollow or shell-shaped load-bearing structural component 2. After the cover element 3 has been inserted into the load-bearing structural component 2, the outer side 33 of the circumferential shell wall 32 of the cover element 3 lies closely adjacent to the inner side 24 of the circumferential shell wall 22 of the load-bearing structural component 2. The gap remaining between the outer side 33 of the circumferential shell wall 32 of the cover element 3 and the inner side 24 of the circumferential shell wall 22 of the load-bearing structural component 2 can be very small, in particular in the range of tenths of a millimeter. In particular, a clearance fit can be provided here between the circumferential shell wall 32 of the cover element 3 and the circumferential shell wall 22 of the load-bearing structural component 2.

[0051] Between the upper side 31 of the cover element 3, which points in the direction of the supporting structural component 2, and the adjacent inner side 25 of the shell-shaped supporting structural component 2, a hollow space remains, forming a fluid channel 4. This can be seen particularly clearly in Figure 3. The multi-dimensional, different shape of the upper side 31 of the cover element 3 with bulged or projecting sections and recessed or trough-shaped sections can lead to different flow cross-sections of the created fluid channel 4 in this area. Figure 3 shows a trough 34 formed on the upper side 31 of the cover element 3. In the area of ​​the trough 34, the flow cross-section d34 for the temperature control medium flowing inside the module housing 10 can be seen. The flow cross-section d 34in the region of the trough 34 essentially corresponds to the flow cross-section dss within the fluid connection device 58. The flow cross-section between the upper side 31 of the cover element 3 and the adjacent inner side 25 of the shell-shaped supporting structural component 2 can be smaller than the flow cross-section dss outside the trough 34, in particular in the bulged or projecting sections of the cover element 3.

[0052] As can be seen in particular from Figures 2b and 2c, the cover element 3 is formed in one piece. It is also fundamentally possible to provide a multi-part cover element or several individual cover elements and to connect them to the supporting structural component 2. Furthermore, it can be seen, in particular also from Figure 1c, that the cover element 3 extends only in the region of the fluid channels 4a to 4e to be formed or already formed. The cover element 3 thus only has a shape such that it covers the supporting structural component 2 in the regions of the fluid channels 4a to 4e to be formed or already formed. The remaining regions of the supporting structural component 2 are not covered by the cover element 3 or are covered only by connecting sections.The cover element 3 accordingly has an inner through-opening 35 and, surrounding it, the corresponding multi-dimensional shape for forming the different flow cross-sections of the fluid channels 4a to 4e, which are formed between the cover element 3 and the supporting structural component 2 in the interior of the module housing 10 after the cover element 3 and the supporting structural component 2 have been joined together.

[0053] As can be seen in particular from Figure 2b, connecting sections 37, 137, 237, 337 are arranged between the multi-dimensionally shaped sections 36, 136, 236, 336, 436 of the cover element 3. The connecting sections are each designed in a flat, web-like manner, as can be seen particularly clearly from the bottom view of the cover element 3 in Figure 2c. If, instead of the one-piece cover element 3, a multi-part cover element or several cover elements 3 were provided and connected to the load-bearing structural component 2, a separation between the individual cover elements in the region of these connecting sections 37, 137, 237, 337 would be possible or provided, in particular in the region of the two large-area connecting sections 37, 137. However, in order to provide the greatest possible rigidity or surface rigidity of the cover element 3, the cover element is preferably one-piece.This also results in high surface rigidity of the entire module housing 10 of the thermal management module 1, formed from the supporting structural component 2 and the cover element 3. The provision of the one-piece cover element, as shown in detail in Figures 2b and 2c, proves to be additionally advantageous with regard to the durability of the weld seam 11. The weld seam 11 can lie in one plane, as can also be seen in particular from Figures 1a and 1b. When providing a multi-part cover element or several cover elements, welding of the cover elements or the multi-part cover element to the supporting structural component 2 in several planes would usually be possible or intended.

[0054] As can be seen in particular from the bottom view of the thermal management module 1 according to Figure 1c, the supporting structural component 2 has a grid-shaped region 26 in the area of ​​the through-opening 35 of the cover element 3. This region serves for thermal decoupling, with the grid-shaped region 26 being formed by webs 126, 127 and openings 128 left between them. The webs 126, 127 each intersect at an angle, which can be a perpendicular angle or a different angle. The intersecting webs 126, 127, together with the openings 128 defined by the webs, form the grid structure. Via the webs 126, 127 and the openings 128, heat conduction across the surface of the supporting structural component 2 can thus be interrupted and thus thermal decoupling of the individual areas of the supporting structural component 2, which together with the cover element 3 form the fluid channels 4a to 4e, is possible.The sections 40, 41, 42, 43, 44 of the load-bearing structural component 2 intended to form the fluid channels 4a, 4b, 4c, 4d, 4e can be seen particularly well in Figure 2d. It can be seen here that the sections 40, 41, 42 are each separated from one another by intermediate walls 45, 46, while the sections 43, 44 are formed separately anyway. As can also be seen in Figure 2d, larger gaps or distances are left between the section 43 and the section 42 or the section 44. These are the areas in which the connecting sections 37 and 137 of the cover element 3 are arranged, so that the cover element 3 has sufficient stability and rigidity in this area as well.

[0055] As can be further seen in Figure 2d, the supporting structural component 2 has three molded-in fastening eyes 29, 129, 229. These serve to fasten the thermal management module 1 in a vehicle or to a vehicle body. Instead of such fastening eyes, other fastening devices or other fastening points on the module housing 10 or, in particular, on the supporting structural component 2 thereof can also be provided.

[0056] As can be seen particularly well from Figures 1, 1a, 1b and 2a, the load-bearing structural component 2 has a number of fluid connection devices, some of which, namely the fluid connection devices 50, 51, 52, 53, 54, 55, 56, 57, 58, extend in the direction of the vertical extent h of the shell-shaped load-bearing structural component 2, while the fluid connection devices 59, 60, 61 extend approximately perpendicular to the outside of the load-bearing structural component 2 or protrude outwards from it. Hoses or pipes, thus media lines, which are in fluid communication with a temperature control circuit of a vehicle or sub-circuits thereof, can be connected to the fluid connection devices 50 to 61. Accordingly, a supply line and a return line of such a sub-circuit of the temperature control circuit of the vehicle are each connected to a respective fluid connection device.Accordingly, after entering through a respective fluid connection device, the temperature control medium can flow into a respective fluid channel 4a, 4b, 4c, 4d, 4e in the module housing 10 of the thermal management module and can also flow out of the module housing 10 or the thermal management module 1 again via a corresponding fluid connection device. In order to transport temperature control medium through the thermal management module or module housing 10 and therefrom, pumping devices 5, 6 can be attached to the supporting structural component 2 of the module housing 10 of the thermal management module 1, as indicated in Figure 1c. In order to connect the two pumping devices 5, 6 orIn order to be able to arrange a suitable number of pumping devices or, in general, components for conveying temperature control medium on the supporting structural component 2 of the module housing 10 of the thermal management module 1, the supporting structural component 2 has two connecting sections 27, 28 for this purpose, which are designed for attaching and connecting the pumping devices 5, 6. These connecting sections 27, 28 are arranged, as can be seen particularly clearly in Figure 2a, or pumping devices 5, 6 on the connecting sections, as can be seen particularly clearly in Figures 1 and 1c, in the region of the fluid channels and, accordingly, in the sections 40, 41, 42, 43, 44 of the supporting structural component 2 provided for their formation.Furthermore, the supporting structural component 2 comprises two additional connection sections 70, 80 for connecting two valves 7, 8 as components for mass flow control, which can also be attached to the supporting structural component 2 of the module housing 10 of the thermal management module 1. The corresponding connection sections 70, 80 and valves 7, 8 thereon can be seen particularly clearly in Figures 1 and 2a, respectively. The connection sections 70, 80 are each arranged in branching regions of the fluid channels inside the module housing 10 in order to be able to distribute mass flows of temperature control medium to the individual fluid connection devices 50 to 61 accordingly.

[0057] In particular, Figure 2a, but also Figure 1, shows that some of the fluid connection devices 50 to 61 are arranged very closely next to one another. Since the module housing or its supporting structural component 2 and cover element 3 are advantageously manufactured from plastic using an injection molding process, the problem indicated in Figure 6 would arise if the individual fluid connection devices were molded directly into the supporting structural component. There, three fluid connection devices 62, 63, 64 are arranged closely next to one another. In order to be able to move them in the injection molding tool, which is also indicated in Figure 6 by its underfloor slides 90, 91, 92, they require sufficient space in the opening direction.However, it can be seen in Figure 6 that during demolding of the manufactured, i.e. injection-molded, load-bearing structural component 2, there would be a collision between the underfloor slide 91 and the fluid connection device 63, since the underfloor slide 91 is positioned between the two injection-molded fluid connection devices 62, 63 and must be removed from the fluid connection device 62 in order to demold the undercuts for holding contours. In doing so, it can be seen, see arrow P1, colliding with the fluid connection device 63, since the distance between the fluid connection device 62 and the fluid connection device 63 is too small for demolding. Such a collision leads to damage to at least the fluid connection device 63, so that demolding of the load-bearing structural component 2 in the region of the fluid connection devices 62, 63 would therefore not be possible without damage.

[0058] To solve this problem, the fluid connection device 62 is designed in two parts, as can be seen particularly clearly in Figures 5a, 5b, and 5c. The fluid connection device 62 is accordingly composed of an annular receiving section 620 formed in the supporting structural component 2 and a fluid connection section 621 formed in the cover element 3. The fluid connection section 621, which is part of the cover element 3, is inserted into the receiving section 620 in the supporting structural component 2, as can be seen in Figure 5c. During injection molding of the supporting structural component, the fluid connection device 63, as well as the receiving section 620, can therefore be easily removed from the mold, since there is no longer any collision between the underfloor slide 91 and the fluid connection device 63.The receiving section 620 is significantly shorter than the fluid connection device 63, which can also be seen from the comparison of Figures 5a, 5c with Figures 4a, 4c, in which both fluid connection devices 62, 63 are formed as a single piece. The underfloor slide used to form the fluid connection device 63 can be easily removed from the fluid connection device 63 without colliding with the receiving section 620 during demolding of the fluid connection device 63.

[0059] In order to achieve a tight connection between the receiving section 620 and the fluid connection section 621 inserted into it, a sealing element 622 is arranged between them, as can also be seen in Figure 5c. Although the injection molding tool is more complex than the injection molding tool shown in Figure 6, since the receiving section 620 on the supporting structural component 2 and the fluid connection section 621 on the cover element 3 must be formed separately, i.e., a corresponding fluid connection device must be formed not only on the supporting structural component 2, the two-part design of one or more fluid connection devices, here the fluid connection device 62, allows for a significant amount of installation space to be gained, allowing a large number of fluid connection devices to be arranged in a small space. Accordingly, a large number of sub-circuits of a vehicle's temperature control circuit can be connected to the thermal management module.

[0060] In addition to the embodiments of thermal management modules for managing mass flows of a temperature control medium in at least one temperature control circuit of a vehicle described above and shown in the figures, numerous others can be provided, in particular any desired combinations of the aforementioned features, wherein the thermal management module in each case comprises at least one module housing which has at least one supporting structural component and at least one cover element, wherein the at least one supporting structural component and the at least one cover element are connected to one another in a fluid-tight manner and at least one fluid channel is formed between the two as a fluid path in the interior of the module housing. The fluid path or the at least one fluid channel in the interior of the module housing is in flow connection orcan be brought into flow connection with these.

[0061] List of reference symbols

[0062] 1 thermal management module

[0063] 2 load-bearing structural component

[0064] 3 cover element

[0065] 4 fluid channel

[0066] 4a Fluid channel

[0067] 4b Fluid channel

[0068] 4c Fluid channel

[0069] 4d fluid channel

[0070] 4e Fluid channel

[0071] 5 Pumping device

[0072] 6 Pumping device

[0073] 7 Valve

[0074] 8 valve

[0075] 10 module housings

[0076] 11 Weld seam

[0077] 20 open bottom

[0078] 21 Front side

[0079] 22 circumferential shell wall

[0080] 23 Interior

[0081] 24 inside of 22

[0082] 25 Inside

[0083] 26 grid-shaped area

[0084] 27 connecting section

[0085] 28 connecting section

[0086] 29 Mounting eyelet

[0087] 30 projecting surrounding edge

[0088] 31 Top

[0089] 32 circumferential shell wall

[0090] 33 outside of 32

[0091] 34 trough

[0092] 35 passage opening

[0093] 36 multidimensional shaped section connecting section

[0094] Section

[0095] Section

[0096] Section

[0097] Section

[0098] Section

[0099] partition wall

[0100] partition wall

[0101] Fluid connection device

[0102] Fluid connection device

[0103] Fluid connection device

[0104] Fluid connection device

[0105] Fluid connection device

[0106] Fluid connection device

[0107] Fluid connection device

[0108] Fluid connection device

[0109] Fluid connection device

[0110] Fluid connection device

[0111] Fluid connection device

[0112] Fluid connection device

[0113] Fluid connection device

[0114] Fluid connection device

[0115] Fluid connection device

[0116] Connection section

[0117] Connection section

[0118] Underfloor slide valve

[0119] Underfloor slide valve

[0120] Underfloor slide valve

[0121] web

[0122] web

[0123] opening

[0124] Fastening eyelet multi-dimensional shaped section

[0125] Connecting section 229 fastening eyelet

[0126] 236 multidimensional shaped section

[0127] 237 connecting section

[0128] 336 multidimensional shaped section

[0129] 337 connecting section

[0130] 436 multidimensional shaped section

[0131] 620 recording section

[0132] 621 Fluid connection section

[0133] 622 Sealing element dgi Flow diameter at 31 d34 Flow diameter at 34 h Height extension

[0134] P1 Arrow / Collision

Claims

Claims Thermal management module (1) for managing mass flows of a temperature control medium in at least one temperature control circuit of a vehicle, wherein the thermal management module (1) comprises at least one module housing (10), at least one fluid connection device (50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64) and at least one fluid path in the interior of the module housing (10), characterized in that the module housing (10) comprises at least one supporting structural component (2) and at least one cover element (3), wherein the at least one supporting structural component (2) and the at least one cover element (3) are connectable or connected to one another and form the at least one fluid channel (4, 4a, 4b, 4c, 4d, 4e) as a fluid path between them.Thermal management module (1) according to claim 1, characterized in that the at least one supporting structural component (2) is designed such that at least one component for conveying the temperature control medium (5, 6) and at least one component for regulating the mass flow (7, 8) can be arranged or are arranged thereon or are integrated into it, in particular at least two components for conveying the temperature control medium (5, 6) and at least one component for regulating the mass flow (7, 8). Thermal management module (1) according to claim 2, characterized in that the at least one supporting structural component (2) is designed such that the at least one component for conveying the temperature control medium (5, 6) and the at least one component for regulating the mass flow (7, 8) can be installed or are installed from the same side of the at least one supporting structural component (2). Thermal management module (1) according to claim 1, 2 or 3, characterized in that. the at least one supporting structural component (2) and the at least one cover element (3) are formed in one piece or in multiple parts, in particular are formed in multiple parts, in particular are formed in multiple parts and can be connected or are connected to one another in a materially bonded manner, in particular are connected to one another in a materially bonded manner by laser welding. Thermal management module (1) according to one of the preceding claims, characterized in that the connection region in which the at least one cover element (3) and the at least one supporting structural component (2) are connected to one another lies in one plane. Thermal management module (1) according to one of the preceding claims, characterized in that the cover element (3) is formed in multiple parts and the multi-part cover element (3) can be connected or is connected to the at least one supporting structural component (2) in more than one plane.Thermal management module (1) according to one of the preceding claims, characterized in that the at least one cover element (3) is at least partially trough-shaped for forming different flow cross-sections (dg1, dg4) of the at least one fluid channel (4, 4a, 4b, 4c, 4d, 4e) between the at least one cover element (3) and the at least one supporting structural component (2). Thermal management module (1) according to one of the preceding claims, characterized in that the at least one cover element (3) is shaped differently in several dimensions across its cross-section, in particular bulged in the direction of the supporting structural component (2), for the purpose of optimizing the flow of temperature control medium flowing within the at least one fluid channel (4, 4a, 4b, 4c, 4d, 4e) in the interior of the thermal management module (1). or has projecting sections and recessed or trough-shaped sections (34). Thermal management module (1) according to one of the preceding claims, characterized in that the at least one fluid connection device (50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64) is arranged or formed on the at least one supporting structural component (2) and / or the at least one cover element (3). Thermal management module (1) according to claim 9, characterized in that the at least one fluid connection device (50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64) is formed from at least one receiving section (620) formed in the at least one supporting structural component (2) and at least one fluid connection section (621) formed in the at least one cover element (3) and insertable or inserted into the at least one receiving section (620).Thermal management module (1) according to claim 10, characterized in that at least one sealing element (622) is provided for fluidically sealing the connection between the receiving section (620) and the fluid connection section (621) and can be arranged or is arranged between them. Thermal management module (1) according to one of the preceding claims, characterized in that the at least one supporting structural component (2) is at least partially lattice-shaped, in particular no cover element (3) is provided in the lattice-shaped region(s) (26) of the at least one supporting structural component (2), or the at least one cover element (3) extends outside the at least one lattice-shaped region (26). Vehicle with at least one temperature control circuit for temperature control of vehicle components, in particular at least one battery and at least one electronic component, wherein at least one thermal management module is provided for managing mass flows of a temperature control medium in the at least one temperature control circuit, characterized in that the thermal management module is a thermal management module (1) according to one of the preceding claims.

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