Cooling module

Abstract

A cooling module equipped with a resin manifold comprising a plurality of housings which are joined to one another while having no reserve tank provided therein, wherein said manifold has a plurality of channels which are formed so as to span two or more of the plurality of housings.

Description

Cooling Module

[0001] The present invention relates to a cooling module.

[0002] In recent years, automobiles equipped with motors as a driving source (such as hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), battery electric vehicles (BEVs), and fuel cell electric vehicles (FCEVs)) have become widespread. These automobiles (hereinafter collectively referred to as "electric vehicles") are equipped with batteries to drive the motors. Electric vehicles have many devices that require cooling, such as motors (including internal combustion engines such as engines), batteries, air conditioners, and ECUs. Therefore, cooling circuits that circulate coolant are configured to cool these devices. However, these devices may have different optimum operating temperatures. In such cases, it is necessary to configure independent cooling circuits for each coolant temperature in order to change the temperature of the circulating coolant for each device with a different operating temperature. This results in complex piping and circuit configuration for the cooling circuits.

[0003] To address this issue, for example, there is a technology described in Patent Document 1. The cooling module disclosed in Patent Document 1 (an integrated coolant bottle assembly in Patent Document 1) has a configuration in which components such as a pump, chiller, heater, filter, valve, and fan are attached to a reserve tank (reservoir in Patent Document 1), and flow paths between the components (integral channels in Patent Document 1) are formed integrally with the reserve tank.

[0004] Special table 2019-520261 publication

[0005] In the cooling module disclosed in Patent Document 1, the components are attached to a reserve tank, so they must be attached to fit the shape of the reserve tank, and the only space available for installation is on the surface of the reserve tank. Therefore, the installation space is determined by the capacity of the reserve tank. Installing a pump and valves in this limited installation space restricts the positions and directions of the coolant flow paths, inlet ports, and outlet ports, potentially reducing the design freedom of the cooling circuit. This impacts the positions and directions of the piping attached to the inlet and outlet ports, potentially leaving the piping routing complex.

[0006] The present invention has been made in consideration of the above-mentioned problems, and its purpose is to provide a cooling module in which auxiliary equipment such as pumps and valves are attached and integrated, and the flow paths are organized to align the positions and orientations of the inlet and outlet ports.

[0007] One embodiment of the cooling module of the present invention does not have a reserve tank inside, and is equipped with a resin manifold consisting of multiple housings joined to each other, and the manifold has multiple flow paths formed across at least two of the multiple housings.

[0008] According to this embodiment, the manifold has multiple flow paths formed across at least two housings, thereby reducing the number of pipes. Furthermore, because the manifold is configured by joining multiple housings, the shape of each housing can be simplified even if the flow path shape and flow path configuration within the manifold become complex by considering the position and direction of the ports to which the pipes are connected. This allows the pipes connected to the ports to be consolidated, avoiding redundant routing, thereby shortening and simplifying the length of the pipes connected to the ports. Furthermore, because the cooling module does not have a reserve tank, the cooling module can be configured compactly and the flexibility of the cooling module's placement can be increased. This makes it possible to provide a cooling module in which the flow paths within the manifold are organized and the positions and orientations of the inlet and outlet ports are aligned.

[0009] Another embodiment of the cooling module of the present invention further includes a first accessory and a second accessory that control the flow of fluid through the flow path, and the multiple housings include a first housing and a second housing joined to the first housing, with the first accessory attached to the first housing and the second accessory attached to the second housing.

[0010] According to this embodiment, by attaching the first accessory and the second accessory to different housings, the strength of the housing required to hold the accessory can be optimized depending on the type of accessory.

[0011] In another embodiment of the cooling module of the present invention, the first housing is joined vertically above the second housing, the first housing has a plurality of inlet ports that respectively communicate with a plurality of the flow paths, and the plurality of inlet ports are arranged side by side so that their respective axes are aligned vertically and on the same plane.

[0012] According to this embodiment, by arranging the inlet ports side by side so that their respective axes are aligned vertically and on the same plane, the piping connected to the inlet ports can be consolidated and redundant routing can be avoided, thereby shortening and simplifying the length of the piping connected to the inlet ports.

[0013] In another embodiment of the cooling module according to the present invention, the first accessory is a rotary valve, and a valve body of the rotary valve is located within the second housing.

[0014] According to this embodiment, by positioning the valve body of the rotary valve within the second housing, the flow of fluid circulating through multiple flow paths can be controlled by switching the flow paths formed within the second housing.

[0015] In another embodiment of the cooling module according to the present invention, the second housing has a mounting portion to which the second accessory is attached, and the mounting portion is thicker than other portions.

[0016] According to this embodiment, even if the manifold is made of resin, it is possible to ensure the strength to mount and hold heavy accessories.

[0017] In another embodiment of the cooling module of the present invention, the second accessory is a water pump that pressurizes the fluid, and the water pump and the second housing form a vortex chamber through which the pressurized fluid flows.

[0018] According to this embodiment, the water pump does not require a shroud that regulates the inflow and outflow directions of fluid, making it possible to reduce the size, weight, and cost of the cooling module.

[0019] In another embodiment of the cooling module of the present invention, the multiple flow paths include a first flow path that constitutes part of a first circulation path that circulates through a radiator, a second flow path that constitutes part of a second circulation path that circulates through a heater core, a third flow path that constitutes part of a third circulation path that circulates through a battery, and a communicating flow path that connects the first flow path, the second flow path, and the third flow path.

[0020] According to this embodiment, by providing a first flow path that forms part of the first circulation path, a second flow path that forms part of the second circulation path, a third flow path that forms part of the third circulation path, and a communicating flow path that connects the first flow path, the second flow path, and the third flow path within the cooling module, it is possible to aggregate the circulation paths through which the fluid circulates, thereby reducing the number of pipes connected to the port and shortening and simplifying the piping length.

[0021] In another embodiment of the cooling module according to the present invention, the communication flow path is formed along the joint surfaces of the plurality of housings.

[0022] According to this embodiment, by forming a communicating flow path on the joining surface, the first flow path, the second flow path, and the third flow path can be made to communicate with each other even if they are separated into the first housing and the second housing.

[0023] 3 is a circuit diagram of a cooling system having a cooling module according to this embodiment; FIG. 4 is a perspective view of the cooling module; FIG. 5 is an exploded perspective view of the cooling module; FIG. 6 is a perspective view of the first housing as seen from the joining surface side; FIG. 7 is an exploded perspective view of the cooling module; FIG. 8 is a cross-sectional view taken along the arrows VI-VI in FIG. 3; FIG. 9 is a perspective view of the lower housing as seen from the joining surface side; FIG. 10 is a cross-sectional view taken along the arrows VIII-VIII in FIG. 2; FIG. 11 is a diagram showing a first mode of operation of the cooling system; FIG. 12 is a diagram showing a second mode of operation of the cooling system; FIG. 13 is a diagram showing a third mode of operation of the cooling system; and FIG. 14 is a diagram showing a fourth mode of operation of the cooling system.

[0024] Hereinafter, one embodiment of a cooling module according to the present invention will be described in detail with reference to the drawings. Note that the embodiment described below is an example for explaining the present invention, and the present invention is not limited to only these embodiments. Therefore, the present invention can be embodied in various forms without departing from the gist of the present invention.

[0025] 1, a cooling system A including a cooling module 10 according to this embodiment includes a first water pump 1A (an example of a second auxiliary device), a radiator 1B, an inverter / motor 1C, a DC-DC converter 1D, a charger 1E, a reserve tank 1F, a second water pump 2A (an example of a second auxiliary device), a heater core 2B, an electric heater 2D, a water-cooled condenser 2C, a third water pump 3A (an example of a second auxiliary device), a battery 3B, a chiller 3C, an electric heater 3D, a first rotary valve 4 (an example of a first auxiliary device), a second rotary valve 5 (an example of a first auxiliary device), and a plurality of flow paths for circulating coolant (an example of a fluid) through these components. Of these components, the first water pump 1A, the second water pump 2A, the third water pump 3A, the first rotary valve 4, and the second rotary valve 5 are attached to the cooling module 10. On the other hand, the radiator 1B, inverter / motor 1C, DC-DC converter 1D, charger 1E, reserve tank 1F, heater core 2B, electric heater 2D, water-cooled condenser 2C, battery 3B, chiller 3C, and electric heater 3D are positioned at a distance from the cooling module 10, and are configured so that cooling water circulates between them and the cooling module 10 via multiple flow paths.

[0026] The cooling system A is used in automobiles equipped with a motor as a driving source, such as hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), battery electric vehicles (BEVs), and fuel cell electric vehicles (FCEVs) (hereinafter collectively referred to as "electric vehicles"), and circulates cooling water to cool the inverter / motor 1C, battery 3B, etc.

[0027] The radiator 1B cools the high-temperature coolant. The inverter / motor 1C is a driving source that operates using power supplied from the battery 3B. The DC-DC converter 1D and charger 1E charge the battery 3B. The heater core 2B heats the air using high-temperature coolant to heat the interior of the vehicle. The electric heaters 2D and 3D heat the coolant when its temperature is low. The water-cooled condenser 2C and chiller 3C cool the coolant when its temperature is high. The battery 3B supplies power to the inverter / motor 1C.

[0028] The first water pump 1A pumps coolant to be supplied to the inverter / motor 1C, DC-DC converter 1D, and charger 1E. The second water pump 2A pumps coolant to be supplied to the heater core 2B, electric heater 2D, and water-cooled condenser 2C. The third water pump 3A pumps coolant to be supplied to the battery 3B, chiller 3C, and electric heater 3D. The first water pump 1A, second water pump 2A, and third water pump 3A pump coolant to control the flow of coolant circulating through multiple flow paths.

[0029] Hereinafter, a circulation flow path configured to return from radiator 1B through first water pump 1A, inverter / motor 1C, DC-DC converter 1D, charger 1E, and reserve tank 1F to radiator 1B will be referred to as first circulation path 1 (see FIG. 9 ), and a flow path of first circulation path 1 formed within cooling module 10 will be referred to as first flow path 11. Similarly, a circulation flow path configured to return from heater core 2B through second water pump 2A, water-cooled condenser 2C, and electric heater 2D to heater core 2B will be referred to as second circulation path 2 (see FIG. 9 ), and a flow path of second circulation path 2 formed within cooling module 10 will be referred to as second flow path 21. Similarly, a circulation flow path configured to return from battery 3B through third water pump 3A, chiller 3C, and electric heater 3D to battery 3B will be referred to as third circulation path 3 (see FIG. 9 ), and a flow path of third circulation path 3 formed within cooling module 10 will be referred to as third flow path 31. Furthermore, a communication flow path 51 (an example of a flow path) that connects the first flow path 11, the second flow path 21, and the third flow path 31 is formed within the cooling module 10. The flow path configuration within the cooling module 10 will be described later.

[0030] [Cooling Module Configuration] As shown in Figures 2 to 8, the cooling module 10 includes the first water pump 1A, the second water pump 2A, the third water pump 3A, the first rotary valve 4, the second rotary valve 5, and a manifold 100 having flow paths for circulating coolant through these components of the cooling system A. The manifold 100 is formed by joining and integrating multiple housings, thereby forming multiple flow paths for circulating coolant across at least two housings (in this embodiment, a first housing 110 and a second housing 120, described below). As shown in Figure 1, the cooling module 10 does not have an internal reserve tank. The lack of a reserve tank in the cooling module 10 allows for a compact configuration and increases the flexibility in the placement of the cooling module 10.

[0031] The manifold 100 is formed by joining and integrating a first housing 110 and a second housing 120, both made of resin, using a method such as vibration welding. The manifold 100 has a generally rectangular parallelepiped shape overall. As shown in FIGS. 3 and 4 , a joining surface 105 between the first housing 110 and the second housing 120 is flat. Hereinafter, the direction parallel to the longitudinal direction of the joining surface 105 is defined as the X direction, the direction parallel to the lateral direction of the joining surface 105 is defined as the Y direction, and the direction perpendicular to the joining surface 105 is defined as the Z direction. In other words, the joining surface 105 is parallel to the XY plane. Furthermore, within the X direction, the direction from the first water pump 1A toward the third water pump 3A is defined as the X1 direction, and the opposite direction is defined as the X2 direction. Within the Y direction, the direction from the second outlet port 115 toward the first inlet port 111 is defined as the Y1 direction, and the opposite direction is defined as the Y2 direction (the second outlet port 115 and the first inlet port 111 will be described later). Within the Z direction, the direction from the second housing 120 toward the first housing 110 is defined as the Z1 direction, and the opposite direction is defined as the Z2 direction. The Z2 direction is the direction of gravity. That is, the first housing 110 is disposed vertically above the second housing 120.

[0032] 2 and 3 , the first housing 110 is formed with a first inlet port 111, a second inlet port 112, a third inlet port 113, a first outlet port 114, a second outlet port 115, and a fifth outlet port 116. The second housing 120 is formed with a third outlet port 121, a fourth outlet port 122, and a sixth outlet port 123. The first inlet port 111, the second inlet port 112, the third inlet port 113, the first outlet port 114, the second outlet port 115, the third outlet port 121, the fourth outlet port 122, the fifth outlet port 116, and the sixth outlet port 123 are all cylindrical. The first inlet port 111, the second inlet port 112, and the third inlet port 113 are arranged side by side with their respective axes aligned in the Z direction and on the same plane, and each port has an opening facing the Z1 direction. The first outlet port 114 and the third outlet port 121 are arranged side by side with their respective axes aligned in the X direction and on the same plane, and both ports have openings facing the X2 direction. The second outlet port 115 and the fifth outlet port 116 are arranged side by side with their respective axes aligned in the Y direction and on the same plane, and both ports have openings facing the Y2 direction. The fourth outlet port 122 and the sixth outlet port 123 are also arranged side by side with their respective axes aligned in the Y direction and on the same plane, and both ports have openings facing the Y2 direction.

[0033] The first inlet port 111, the first outlet port 114, and the second outlet port 115 are included in the first circulation path 1, and all of them communicate with the first flow path 11. The second inlet port 112 and the fourth outlet port 122 are included in the second circulation path 2, and all of them communicate with the second flow path 21. The third inlet port 113, the fifth outlet port 116, and the sixth outlet port 123 are included in the third circulation path 3, and all of them communicate with the third flow path 31.

[0034] As shown in FIGS. 2 and 3 , in the manifold 100, the first rotary valve 4 and the second rotary valve 5 are mounted between the first inlet port 111, the second inlet port 112, the third inlet port 113, the second outlet port 115, and the fifth outlet port 116 in the first housing 110 when the first housing 110 is viewed in the Z2 direction. In the first rotary valve 4 and the second rotary valve 5, the first actuator 4B that rotates the first valve element 4A of the first rotary valve 4 and the second actuator 5B that rotates the second valve element 5A of the second rotary valve 5 are exposed at the top of the first housing 110. Both the first valve element 4A and the second valve element 5A are located within the second housing 120 (see FIG. 6 ). This allows the flow of cooling water circulating through multiple flow paths to be controlled by switching between flow paths formed within the second housing 120. The first rotary valve 4 and the second rotary valve 5 are both solenoid valves whose flow paths are switched by an actuator, and the flow of cooling water circulating through multiple flow paths is controlled by rotating the first valve body 4A and the second valve body 5A around an axis along the Z direction to switch the flow paths. The first valve body 4A is a three-way valve, and the second valve body 5A is a four-way valve. Details will be described later.

[0035] As shown in FIGS. 2 and 3 , in the manifold 100, the first water pump 1A, the second water pump 2A, and the third water pump 3A are attached to the second housing 120 in this order along the X1 direction. The first water pump 1A, the second water pump 2A, and the third water pump 3A are arranged so that their respective rotational axes are aligned along the Y direction. The second housing 120 is formed with a first downward sub-channel 11a (an example of a channel) that communicates with the first inlet port 111 and extends in the Z direction, a second downward sub-channel 21a (an example of a channel) that communicates with the second inlet port 112 and extends in the Z direction, and a third downward sub-channel 31a (an example of a channel) that communicates with the third inlet port 113 and extends in the Z direction. The first downward sub-channel 11a, the second downward sub-channel 21a, and the third downward sub-channel 31a are formed across the first housing 110 and the second housing 120. The first water pump 1A pumps coolant that flows in through the first downward sub-channel 11a from the first inlet port 111. The second water pump 2A pumps coolant that flows in through the second downward sub-channel 21a from the second inlet port 112. The third water pump 3A pumps coolant that flows in through the third downward sub-channel 31a from the third inlet port 113. The first downward sub-channel 11a is part of the first channel 11, the second downward sub-channel 21a is part of the second channel 21, and the third downward sub-channel 31a is part of the third channel 31.

[0036] 5, the first water pump 1A, the second water pump 2A, and the third water pump 3A are attached to a mounting portion 125 formed at the end of the second housing 120 in the Z2 direction (the lower end in the vertical direction). The mounting portion 125 is thicker than other portions of the second housing 120. This ensures that the second housing 120, which is made of resin, is strong enough to mount and hold the heavy first water pump 1A, the second water pump 2A, and the third water pump 3A.

[0037] Mounting portion 125 is formed with a first vortex chamber 1Aa in which coolant flowing into first water pump 1A from first downward sub-passage 11a swirls after being discharged by the rotation of the impeller (not shown), a second vortex chamber 2Aa in which coolant flowing into second water pump 2A from second downward sub-passage 21a swirls after being discharged by the rotation of the impeller, and a third vortex chamber 3Aa in which coolant flowing into third water pump 3A from third downward sub-passage 31a swirls after being discharged by the rotation of the impeller. Because mounting portion 125 thus has first vortex chamber 1Aa, second vortex chamber 2Aa, and third vortex chamber 3Aa, shrouds for restricting the inflow and outflow directions of coolant are not required for first water pump 1A, second water pump 2A, and third water pump 3A, which enables reduction in size, weight, and cost of cooling module 10.

[0038] As described above, in the cooling module 10, the manifold 100 has multiple flow paths formed across the first housing 110 and the second housing 120, making it possible to reduce the number of pipes. Furthermore, because the manifold 100 is configured by joining the first housing 110 and the second housing 120, even if the flow path shape and flow path configuration within the manifold 100 become complex by considering the position and direction of the ports to which the pipes are connected, it is possible to simplify the shapes of the first housing 110 and the second housing 120. This makes it possible to consolidate the pipes connected to the ports and avoid redundant routing, thereby shortening and simplifying the length of the pipes connected to the ports.

[0039] [Coolant Flow in Cooling Module] Next, the flow of coolant in the cooling module 10 will be described using Figures 3 and 6 to 8. First, the flow of coolant in the first circulation path 1 (see Figure 9) will be described. As shown in Figure 3, the coolant cooled by the radiator 1B enters the second housing 120 of the cooling module 10 through the first inlet port 111, flows through the first downward sub-channel 11a in the Z2 direction, and flows into the first water pump 1A. The coolant pumped by the first water pump 1A flows in the Z1 direction through the first upward sub-channel 11b (an example of a channel) formed along the Z direction, and a first lateral sub-channel 11c (an example of a channel) branches off from the first upward sub-channel 11b at the joint surface 105 between the first housing 110 and the second housing 120. As described above, the first outlet port 114 is formed in the first housing 110, and therefore the coolant that flows in the Z1 direction through the upward first sub-flow path 11b from the second housing 120 to the first housing 110 then changes its flow direction to the X2 direction and flows out from the first outlet port 114. The coolant that flows out of the cooling module 10 from the first outlet port 114 cools the DC-DC converter 1D and the charger 1E, and returns to the radiator 1B via the reserve tank 1F (see FIG. 1).

[0040] The first lateral sub-channel 11c is formed across the first housing 110 and the second housing 120, extending along the Y direction. That is, the first lateral sub-channel 11c is formed along the joining surface 105 between the first housing 110 and the second housing 120. The upper half of the first lateral sub-channel 11c is formed in the first housing 110, and the lower half is formed in the second housing 120. The first lateral sub-channel 11c is formed by joining the first housing 110 and the second housing 120. The coolant flows through the first lateral sub-channel 11c in the Y2 direction and flows out of the cooling module 10 from a second outlet port 115 provided at the downstream end of the first lateral sub-channel 11c. The coolant flowing out from the second outlet port 115 cools the inverter / motor 1C and returns to the radiator 1B via the reserve tank 1F (see FIG. 1 ). The first upward sub-channel 11 b and the first horizontal sub-channel 11 c form part of the first channel 11 .

[0041] Next, the flow of coolant in the second circulation passage 2 (see FIG. 9 ) will be described. As shown in FIG. 3 , coolant cooled by the heater core 2B enters the second housing 120 of the cooling module 10 through the second inlet port 112, flows through the second downward sub-passage 21a in the Z2 direction, and then flows into the second water pump 2A. Coolant pumped by the second water pump 2A flows through the second upward sub-passage 21b, which is formed along the Z direction, in the Z1 direction. A first auxiliary chamber 4D, which is a space connected to the second upward sub-passage 21b, is formed at the downstream end of the second upward sub-passage 21b. The first auxiliary chamber 4D is positioned adjacent to the first valve chamber 4C of the first rotary valve 4 in the Y1 direction. The first auxiliary chamber 4D is connected to the first valve chamber 4C via a first communication hole 131 that opens along the Y direction. By providing the first auxiliary chamber 4D, the flow direction of the coolant flowing in the Z1 direction through the upward second sub-channel 21b can be changed to the Y2 direction, and the coolant can flow into the first valve chamber 4C from the first communication hole 131. The first valve chamber 4C and the first auxiliary chamber 4D are formed across the second housing 120 and the first housing 110.

[0042] As shown in FIG. 6 , the first valve chamber 4C accommodates the first valve element 4A so that it can rotate about an axis extending along the Z direction. All of the coolant flowing through the upward second sub-channel 21b flows into the first valve chamber 4C via the first auxiliary chamber 4D and the first communication hole 131. The first valve chamber 4C communicates with the lateral second sub-channel 21c via a second communication hole 132 that opens along the Y direction and with the fourth channel 41 via a third communication hole 133 that opens along the X direction. By rotating the first valve element 4A to switch the channel, the coolant flowing into the first valve chamber 4C flows through either the lateral second sub-channel 21c or the fourth channel 41. In the state shown in FIG. 6 , the coolant flows through the fourth channel 41. The lateral second sub-channel 21c extends along the Y direction, and the fourth channel 41 extends along the X direction. Both are formed within the second housing 120 (see FIG. 3 ). The downward second sub-channel 21a, the upward second sub-channel 21b, the lateral second sub-channel 21c, the first valve chamber 4C, and the first auxiliary chamber 4D constitute part of the second channel 21, but the fourth channel 41 is not part of the second channel 21 and does not constitute the second circulation channel 2.

[0043] The cooling water that flows from the first valve chamber 4C into the second lateral sub-channel 21c via the second communication hole 132 flows in the Y2 direction and exits the cooling module 10 through the fourth outlet port 122. The cooling water that flows out from the fourth outlet port 122 passes through the water-cooled condenser 2C and the electric heater 2D and returns to the heater core 2B (see FIG. 1). The cooling water that flows from the first valve chamber 4C into the fourth channel 41 via the third communication hole 133 flows in the X2 direction and exits the cooling module 10 through the third outlet port 121. The cooling water that flows out from the second outlet port 115 flows into the radiator 1B via the reserve tank 1F (see FIG. 1). The first rotary valve 4 rotates the first valve body 4A around an axis along the Z direction using the first actuator 4B, thereby switching the cooling water that has flowed through the upward second sub-channel 21b and into the first valve chamber 4C to flow through the horizontal second sub-channel 21c and the fourth channel 41.

[0044] Next, the flow of coolant in the third circulation path 3 (see FIG. 9 ) will be described. As shown in FIG. 3 , the coolant that has cooled the battery 3B enters the second housing 120 of the cooling module 10 through the third inlet port 113, flows through the downward third sub-channel 31a in the Z2 direction, and then flows into the third water pump 3A. The coolant pumped by the third water pump 3A flows through the upward third sub-channel 31b, which is formed along the Z direction, in the Z1 direction. A second auxiliary chamber 5D, which is a space that communicates with the upward third sub-channel 31b, is formed at the downstream end of the upward third sub-channel 31b. The second auxiliary chamber 5D is positioned adjacent to the second valve chamber 5C of the second rotary valve 5 in the Y1 direction. The second auxiliary chamber 5D communicates with the second valve chamber 5C via a fourth communication hole 134 that opens along the Y direction. By providing the second auxiliary chamber 5D, the flow direction of the coolant flowing in the Z1 direction through the upward third sub-channel 31b can be changed to the Y2 direction, and the coolant can flow into the second valve chamber 5C from the fourth communication hole 134. The second valve chamber 5C and the second auxiliary chamber 5D are formed across the second housing 120 and the first housing 110.

[0045] As shown in FIG. 6 , the second valve chamber 5C accommodates the second valve element 5A so as to be rotatable about an axis extending along the Z direction. All of the coolant flowing through the upward third sub-channel 31b flows into the second valve chamber 5C via the second auxiliary chamber 5D and the fourth communication hole 134. The second valve chamber 5C communicates with the lateral third sub-channel 31d via a sixth communication hole 136 that opens along the Y direction. The second valve chamber 5C also communicates with the third auxiliary chamber 5E and the fourth auxiliary chamber 5F, respectively, via a fifth communication hole 135 and a seventh communication hole 137 that open adjacently on both circumferential sides of the sixth communication hole 136. The third auxiliary chamber 5E and the fourth auxiliary chamber 5F are formed across the second housing 120 and the first housing 110. By rotating the second valve body 5A to switch the flow path, the cooling water that has flowed into the second valve chamber 5C flows to any one of the third lateral sub-flow path 31d, the third auxiliary chamber 5E, and the fourth auxiliary chamber 5F. In the state shown in FIG. 6 , the cooling water flows to the third auxiliary chamber 5E.

[0046] As shown in FIG. 8 , the third auxiliary chamber 5E is connected to the fifth outlet port 116 via the L-shaped third sub-channel 31c extending along the Z direction. By providing the third auxiliary chamber 5E, the flow direction of the cooling water flowing from the second valve chamber 5C through the fifth communication hole 135 into the third auxiliary chamber 5E in a direction perpendicular to the Z direction can be changed to the Z1 direction, and the cooling water can flow through the L-shaped third sub-channel 31c and be discharged from the fifth outlet port 116 to the outside of the cooling module 10. The cooling water that flows out of the fifth outlet port 116 returns to the battery 3B via the electric heater 3D (see FIG. 1 ). The cooling water that flows from the second valve chamber 5C into the lateral third sub-channel 31d through the sixth communication hole 136 flows in the Y2 direction and is discharged from the cooling module 10 through the sixth outlet port 123. The cooling water that flows out of the sixth outlet port 123 returns to the battery 3B via the chiller 3C (see FIG. 1 ). The downward third sub-channel 31a, the upward third sub-channel 31b, the L-shaped third sub-channel 31c, the lateral third sub-channel 31d, the second valve chamber 5C, the second auxiliary chamber 5D, and the third auxiliary chamber 5E constitute part of the third channel 31.

[0047] 3 and 7 , the fourth auxiliary chamber 5F is in communication with a communication flow path 51 that extends from the fourth auxiliary chamber 5F in the Z direction and then bends and extends in the X direction. A first portion 51a of the communication flow path 51 that extends in the Z direction is formed in the second housing 120, and a second portion 51b that extends in the X direction is formed across the first housing 110 and the second housing 120. In other words, the second portion 51b of the communication flow path 51 is formed along the joint surface 105 between the first housing 110 and the second housing 120, and the upper half of the second portion 51b is formed in the first housing 110 and the lower half is formed in the second housing 120. The communication flow path 51 is not part of the third flow path 31 and does not constitute the third circulation path 3.

[0048] As described above, the communication flow path 51 connects the first flow path 11, the second flow path 21, and the third flow path 31 within the cooling module 10. By providing the communication flow path 51 in this way, it is possible to aggregate the three circulation paths through which the cooling water circulates, thereby reducing the number of pipes connected to the ports and shortening and simplifying the pipe lengths.

[0049] The second portion 51b of the communication channel 51 is connected to the first lateral sub-channel 11c at the end opposite the fourth pre-chamber 5F. When viewed along the Z direction, the second portion 51b intersects with the second lateral sub-channel 21c. The second portion 51b is recessed in the Z2 direction, thereby connecting to the second lateral sub-channel 21c at the intersection.

[0050] The second rotary valve 5 rotates the second valve body 5A around an axis along the Z direction using the second actuator 5B, and thereby the cooling water that has flowed into the second valve chamber 5C from the upward third sub-channel 31b can be switched to one of three flow paths: (1) through the fifth communication hole 135, the third auxiliary chamber 5E, and the L-shaped third sub-channel 31c, and then out through the fifth outlet port 116; (2) through the seventh communication hole 137, the fourth auxiliary chamber 5F, and the communicating channel 51, and then out through the second outlet port 115; or (3) through the seventh communication hole 137, the fourth auxiliary chamber 5F, the communicating channel 51, and the lateral second sub-channel 21c, and then out through the second outlet port 115 and the fourth outlet port 122, and also through the sixth communication hole 136, the lateral third sub-channel 31d, and then out through the sixth outlet port 123.

[0051] [Usage of the Cooling System] Next, a usage mode of the cooling system A while the electric vehicle is running will be described. First, a usage mode (hereinafter referred to as the first mode) of the cooling system A when the temperature of the cooling system A is extremely low (e.g., below 0°C) and the electric vehicle is running will be described using FIG. 9 . This corresponds to, for example, a state immediately after the electric vehicle is started running at an extremely low ambient temperature without warming up. In this state, the inverter / motor 1C, DC-DC converter 1D, and charger 1E require the supply of cooled coolant, while the heater core 2B and battery 3B require the supply of heated coolant. Therefore, in the first mode, the first circulation path 1, the second circulation path 2, and the third circulation path 3 operate independently. Hereinafter, in FIGS. 9 to 12 , the first circulation path 1, the second circulation path 2, and the third circulation path 3 are each indicated by thick solid lines.

[0052] In the first circulation path 1, the first water pump 1A is operating, and the coolant that has flowed from the radiator 1B into the first inlet port 111 is pressure-fed by the first water pump 1A, circulates through the first flow path 11, flows out from the first outlet port 114 and the second outlet port 115, and returns to the radiator 1B via the reserve tank 1F. The coolant is cooled by the radiator 1B, and therefore the inverter / motor 1C, DC-DC converter 1D, and charger 1E are cooled.

[0053] In the second circulation path 2, the second water pump 2A is operated and the first rotary valve 4 is switched to connect the first valve chamber 4C and the second lateral sub-path 21c (see FIG. 6 ). The coolant that flows from the heater core 2B into the second inlet port 112 is pumped by the second water pump 2A, flows through the second path 21, and flows out from the fourth outlet port 122. The coolant that flows out of the cooling module 10 is heated by the electric heater 2D and returns to the heater core 2B. At this time, the water-cooled condenser 2C is not operating.

[0054] In the third circulation path 3, the third water pump 3A is operated and the second rotary valve 5 is switched to connect the second valve chamber 5C and the third auxiliary chamber 5E (see FIG. 6 ). The coolant that flows from the battery 3B into the third inlet port 113 is pumped by the third water pump 3A, flows through the third flow path 31, and flows out from the fifth outlet port 116. The coolant that flows out of the cooling module 10 is heated by the electric heater 3D and returns to the battery 3B. This warms the battery 3B with the coolant.

[0055] Next, a usage mode (hereinafter referred to as the second mode) of the cooling system A when the electric vehicle is running at a low temperature (e.g., 0 to 10 degrees Celsius) but higher than cryogenic temperatures will be described with reference to FIG. 10 . This corresponds to, for example, a state in which the ambient temperature is cryogenic and the electric vehicle is running to warm up slightly. In this state, too, cooled coolant must be supplied to the inverter / motor 1C, DC-DC converter 1D, and charger 1E, while heated coolant must be supplied to the heater core 2B and battery 3B. In the second mode, the first circulation path 1 and the second circulation path 2 circulate coolant in the same manner as in the first mode, and therefore a detailed description thereof will be omitted.

[0056] In the third circulation path 3, the third water pump 3A is activated and the second rotary valve 5 is switched to connect the second valve chamber 5C and the fourth auxiliary chamber 5F (the second valve body 5A is rotated 90 degrees clockwise from the state shown in FIG. 6 ). The coolant that flows into the third inlet port 113 from the battery 3B is pumped by the third water pump 3A and flows into the second valve chamber 5C. Then, the coolant flows from the fourth auxiliary chamber 5F through the communication passage 51 and flows out through the second outlet port 115. At this time, the coolant flowing through the communication passage 51 does not flow into the second lateral sub-passage 21c. The coolant that flows out of the cooling module 10 flows through the inverter / motor 1C, reserve tank 1F, and radiator 1B and returns to the battery 3B through the chiller 3C. However, the chiller 3C is not activated, and the coolant is not cooled by the chiller 3C. In the second embodiment, the first circulation path 1 and the third circulation path 3 are integrated to circulate the coolant, and the coolant heated by the inverter / motor 1C, the DC-DC converter 1D, and the charger 1E is used to warm the battery 3B. Note that the flow path connecting the radiator 1B and the chiller 3C branches midway, and a portion of the coolant flows into the first inlet port 111. This constitutes the first circulation path 1 of the first embodiment.

[0057] Next, a usage mode (hereinafter referred to as the third mode) of the cooling system A when the electric vehicle is running at a normal temperature (e.g., 10 to 30 degrees Celsius), which is higher than a low temperature, will be described with reference to FIG. 11 . This corresponds to, for example, a state in which the electric vehicle is running and has completed warming up (normal running state). In the third mode, the first circulation path 1 circulates the coolant in the same manner as in the first mode, and therefore a detailed description thereof will be omitted. Meanwhile, because the second water pump 2A and the third water pump 3A are not operating, the coolant does not flow (return) through the second circulation path 2 and the third circulation path 3.

[0058] Next, a usage mode (hereinafter referred to as the fourth mode) of the cooling system A when the electric vehicle is running at a higher temperature (e.g., 30°C or higher) than normal will be described with reference to FIG. 12 . This corresponds to, for example, a state in which the electric vehicle is run for a long period of time in an environment in which the inverter / motor 1C requires high torque. In this state, the inverter / motor 1C, DC-DC converter 1D, charger 1E, and battery 3B are in a high-temperature state and therefore require the supply of cooling water to cool them. In the fourth mode, the first circulation path 1 circulates cooling water in the same manner as in the first mode, and therefore a detailed description thereof will be omitted.

[0059] In the second circulation path 2, the second water pump 2A is operated and the first rotary valve 4 is switched to connect the first valve chamber 4C and the fourth flow path 41 (the first valve body 4A is rotated 90 degrees counterclockwise from the state shown in FIG. 6 ). The coolant that flows from the heater core 2B into the second inlet port 112 is pumped by the second water pump 2A, flows through the second upward sub-flow path 21b, the first valve chamber 4C, and the fourth flow path 41, and flows out from the third outlet port 121. As described above, the coolant that flows out of the cooling module 10 from the third outlet port 121 flows into the radiator 1B via the reserve tank 1F. The coolant that flows into the radiator 1B and is cooled flows into the first inlet port 111 that constitutes the first circulation path 1. After being pumped by the first water pump 1A, the coolant flows through the first upward sub-channel 11b, the first lateral sub-channel 11c, the connecting channel 51, and the second lateral sub-channel 21c, and is discharged from the cooling module 10 through the fourth outlet port 122. The coolant is then cooled by the water-cooled condenser 2C and returned to the heater core 2B. At this time, the electric heater 2D is not operating. In the fourth mode, the second circulation channel 2 circulates and cools the coolant together with the first circulation channel 1. At this time, a portion of the coolant flowing out of the radiator 1B flows into the chiller 3C.

[0060] In the third circulation path 3, the third water pump 3A is operated and the second rotary valve 5 is switched to connect the second valve chamber 5C and the third lateral sub-path 31d (the second valve body 5A is rotated 45 degrees clockwise from the state shown in Figure 6), and the coolant that flows from the battery 3B into the third inlet port 113 is pressurized by the third water pump 3A and flows into the second valve chamber 5C, and then flows into the third lateral sub-path 31d.

[0061] The cooling water that has flowed into the third lateral sub-channel 31d flows out from the sixth outlet port 123. The cooling water that has flowed out of the cooling module 10 flows back to the battery 3B through the chiller 3C. At this time, the cooling water is cooled by the chiller 3C.

[0062] As described above, in the cooling module 10, all inlet ports are formed along the Z direction, and all outlet ports are formed along the X direction or the Y direction. In particular, the first inlet port 111, the second inlet port 112, and the third inlet port 113 are arranged side by side so that their respective axes are aligned along the Z direction and on the same plane. The first outlet port 114 and the third outlet port 121 are arranged side by side so that their respective axes are aligned along the X direction and on the same plane. Furthermore, the second outlet port 115 and the fifth outlet port 116 are arranged side by side so that their respective axes are aligned along the Y direction and on the same plane. The fourth outlet port 122 and the sixth outlet port 123 are also arranged side by side so that their respective axes are aligned along the Y direction and on the same plane. By aligning the orientations and arrangements of the multiple inlet ports and outlet ports in this way, the piping connected to the inlet ports and outlet ports can be consolidated, avoiding redundant routing, thereby shortening and simplifying the piping length of the circuit in the cooling system A.

[0063] Other Embodiments (1) In the present embodiment, the manifold 100, the first lateral sub-channel 11c, and the communicating channel 51 are formed by joining two members, the first housing 110 and the second housing 120. However, this is not limited to this. At least one of the manifold 100, the first lateral sub-channel 11c, and the communicating channel 51 may be formed by joining three or more members. (2) In the present embodiment, the first water pump 1A, the second water pump 2A, the third water pump 3A, the first rotary valve 4, and the second rotary valve 5 are used as the accessories attached to the cooling module 10. However, this is not limited to this, and other accessories may be attached. Other examples of accessories include pumps such as a battery pump and a powertrain pump, a chiller 3C, electric heaters 2D and 3D, filters, aerators, valves, connectors, fans, and a radiator 1B. (3) In the present embodiment, the manifold 100 is provided with flow paths such as the first flow path 11, the second flow path 21, the third flow path 31, the fourth flow path 41, and the communication flow path 51, but this is not limited to this. The number and arrangement of the flow paths, including the communication paths, in the manifold 100, as well as the positions, opening directions, and number of inlet and outlet ports, can be changed as appropriate depending on the type and number of accessories and the configuration of the cooling circuit.

[0064] The present invention can be used in a cooling module.

[0065] DESCRIPTION OF SYMBOLS 1: First circulation path 1A: First water pump (second accessory) 1Aa: First vortex chamber 1B: Radiator 2: Second circulation path 2A: Second water pump (second accessory) 2Aa: Second vortex chamber 2B: Heater core 3: Third circulation path 3A: Third water pump (second accessory) 3Aa: Third vortex chamber 3B: Battery 4: First rotary valve (first accessory) 5: Second rotary valve (first accessory) 10: Cooling module 11: First flow path 21: Second flow path 31: Third flow path 11a: Downward first sub-flow path (flow path) 11b: Upward first sub-flow path (flow path) 11c: First sub-flow path (flow path) 21a: Downward second sub-flow path (flow path) 31a: Downward third sub-flow path (flow path) 51: Communication flow path (flow path) 100: Manifold 105: Joint surface 110: First housing (housing) 111: First inlet port 112: Second inlet port 113: Third inlet port 120: Second housing (housing) 125: Mounting portion

Claims

1. It does not have a reserve tank inside, and is equipped with a resin manifold consisting of multiple housings joined together, The manifold is a cooling module having a plurality of flow paths formed across at least two of the housings.

2. The fluid passage further includes a first auxiliary device and a second auxiliary device for controlling a flow of a fluid passing through the flow path, The plurality of housings include a first housing and a second housing joined to the first housing, The cooling module of claim 1 , wherein the first accessory is mounted to the first housing and the second accessory is mounted to the second housing.

3. The first housing is joined to the upper side of the second housing in the vertical direction, The first housing has a plurality of inlet ports each communicating with a corresponding one of the flow paths, 3. The cooling module according to claim 2, wherein the inlet ports are arranged in parallel such that their respective axes are aligned vertically and on the same plane.

4. the first accessory is a rotary valve; The cooling module according to claim 3 , wherein a valve body of the rotary valve is located within the second housing.

5. the second housing has a mounting portion to which the second accessory is attached, The cooling module according to claim 2 , wherein the mounting portion is thicker than other portions.

6. the second accessory is a water pump that pumps the fluid, 3. The cooling module according to claim 2, wherein the water pump and the second housing define a vortex chamber through which the pressurized fluid flows.

7. 7. The cooling module according to claim 1, wherein the plurality of flow paths include a first flow path constituting a part of a first circulation path that circulates through a radiator, a second flow path constituting a part of a second circulation path that circulates through a heater core, a third flow path constituting a part of a third circulation path that circulates through a battery, and a communicating flow path that connects the first flow path, the second flow path, and the third flow path.

8. The cooling module according to claim 7 , wherein the communication passage is formed along joint surfaces of the plurality of housings.