Thermal management module

Abstract

The invention relates to a thermal management module (1), comprising a supporting structural component (4), media paths (12), at least one valve (6, 8) for controlling mass flows of at least one temperature-control medium along at least one media path (12), at least one pump (7) for conveying temperature-control medium along at least one media path (12), at least one actuator (9, 90, 91, 92) for setting and adjusting the at least one valve (6, 8), and at least one sensor element (18), wherein the supporting structural component (4) serves to separate regions with media flowing through and regions without media flowing through, and has a media-guiding side (43) with media paths (12) or first profiled parts (44) of media paths (12) and a dry side (42) opposite the media-guiding side (43) with electrical and / or electronic and / or mechanical components (6, 7, 8, 9, 19, 90, 91, 92, 190) that are / can be arranged therein or thereon. In a battery-powered electric vehicle having at least one cooler (100) through which air can flow and at least one thermal management module, the at least one thermal management module is a thermal management module (1) of this type, which is arranged on or in the region of the cooler through which air can flow.

Description

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

[0002] The invention relates to a thermal management module comprising at least one load-bearing structural component, media channels, at least one valve for controlling mass flows of at least one temperature control medium along at least one media channel, at least one pump for conveying temperature control medium along at least one media channel, and at least one actuator for actuating orAdjusting at least one valve, comprising in particular at least one load-bearing structural component, at least two valves for controlling mass flows of at least one temperature control medium and at least two pumps for conveying temperature control medium in at least one temperature control circuit of a battery electric vehicle, a thermal management module, comprising controllable electrical and electronic components, in particular valves for controlling mass flows and pumps for conveying temperature control medium, and a battery electric vehicle with at least one air-flowable radiator and at least one such thermal management module.

[0003] In today's battery-electric vehicles, i.e., electric vehicles and hybrid vehicles, an increasing number of electronically controlled components, such as electrically adjustable control valves, electrically adjustable pumps, and numerous sensors, 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 range optimization. The temperature control medium used is circulated within a closed system of the vehicle's temperature control circuit. Such a temperature control circuit includes, for example...The system comprises at least a first sub-circuit used for temperature control of a traction battery, at least a second sub-circuit used for temperature control of at least one electronic component, and, in particular, at least a third sub-circuit comprising a main heat exchanger for absorbing heat from the vehicle's ambient air and transferring heat to it. The heat exchanger is also circulated by the temperature control medium, allowing heat transfer into and out of the temperature control medium and into the ambient air via the main heat exchanger. The main heat exchanger includes, in particular, an air-flowable cooler. The third sub-circuit, in conjunction with other sub-circuits, can also be used to regulate the climate comfort of the vehicle's interior or cabin. Each sub-circuit has a supply line and a return line.Conventional thermal management systems are very complex, as they comprise multiple cooling circuits with numerous components such as pumps, valves, actuators for controlling the valves, etc., with the cooling circuits being interconnected and nested within each other. Therefore, the provision of thermal management modules is also known, where such modules include at least one load-bearing structural component on which at least one component for conveying the temperature control medium and at least one component for controlling the mass flow rate of the temperature control medium, such as coolant, are mounted.

[0004] A thermal management module for handling a fluid within a vehicle, in particular a vehicle that is at least partially electrically powered, is known from EP 3 746 322 B1. This module comprises a first distribution element, essentially plate-shaped, and a second distribution element, arranged essentially parallel to the first distribution element. The first distribution element and / or the second distribution element comprise, at least partially, a fluid handling element in the form of electromechanical valves, pumps, sensors, inlets, outlets, and channels for guiding the fluid between the inlets, outlets, valves, pumps, sensors, and between or through the distribution elements. The first distribution element and the second distribution element comprise, at least partially, plastic. Inlets and outlets are integrally formed in the first distribution element.Channels are partially integrated into the first and second distribution elements and are fully formed when the distribution elements are connected. Valves, pumps, and sensors are only partially integrated into the distribution elements and are completed by auxiliary elements that are connected to, partially routed through, and / or inserted into the distribution elements.

[0005] EP 4 077 991 B1 discloses a device for handling fluid of an at least partially electrically powered vehicle, comprising a valve assembly with a valve housing, wherein the valve housing has two radially arranged connection openings and one axially arranged connection opening for the inflow and / or outflow of fluid, a valve body which is arranged within the valve housing and is rotatable about an axial axis of rotation, wherein the valve body has a first arcuate connecting channel for connecting two radially arranged connection openings and a second arcuate connecting channel for connecting a radially arranged connection opening with an axially arranged connection opening, wherein the two radially arranged connection openings define a base plane which is orthogonal to the axial axis of rotation.and the first arc-shaped connecting channel defines a first connecting channel plane. The first connecting channel plane has a first angle of inclination relative to the base plane, which is greater than 0°. The device comprises a first housing section and a second housing section, wherein the first housing section and the second housing section are adjacent to each other by a fluidically impermeable contour wall. The contour wall is formed in one piece. It is simultaneously the outer wall of the second housing section, whereby the outer wall is identical to the side of the second housing section oriented towards the first housing section.

[0006] Although the thermal management module in particular is designed to be very space-optimized according to EP 3 746 322 B1, it is also very complex, making the assembly of the numerous components on the thermal management module or its distribution elements time-consuming.

[0007] The present invention is therefore based on the objective of improving a thermal management module, comprising a load-bearing structural component, media paths, at least one valve for controlling mass flows of at least one temperature control medium along at least one media path, at least one pump for conveying temperature control medium along at least one media path, at least one actuator for opening and adjusting the at least one valve and at least one sensor element, such as a temperature sensor, in such a way that it is less complex and at the same time cost-effective and simple in design and enables quick and uncomplicated assembly.

[0008] The problem is solved for a thermal management module according to the preamble of claim 1 in that the supporting structural component serves to separate media-flowing areas and non-media-flowing areas and has a media-carrying side with media channels or first partial profiles of media channels and a dry side opposite the media-carrying side with electrical and / or electronic and / or mechanical components that can be arranged on or therein. For a battery-electric vehicle with at least one air-flowing radiator and at least one thermal management module, the problem is solved in that the at least one thermal management module is such a thermal management module that is arranged on or in the area of ​​the air-flowing radiator. Further developments of the invention are defined in the dependent claims.

[0009] This creates a thermal management module that includes a load-bearing structural component. This component allows for the separation of media-flowing and non-media-flowing areas. This separation is achieved by the load-bearing structural component comprising a media-carrying side with media channels or initial media channel profiles, and a dry side on the opposite side where electrical, electronic, or mechanical components can be mounted, or already are mounted. Due to this clear separation between the media-carrying and dry sides of the load-bearing structural component, the at least one pump and at least one actuator can be easily mounted on the dry side of the load-bearing structural component, and the at least one valve can be mounted from the media-carrying side of the load-bearing structural component in just a few assembly steps.The load-bearing structural component advantageously comprises at least one through-opening for the passage of at least one mechanical drive section of a fluid-carrying component, such as at least one valve, from the fluid-carrying side of the load-bearing structural component to its dry side, wherein a seal for the fluid-carrying component can be provided or is provided on the fluid-carrying side of the load-bearing structural component. Such a mechanical drive section of a fluid-carrying component, such as at least one valve, can, for example, be its drive shaft. This shaft thus projects from the fluid-carrying side of the load-bearing structural component through it to its dry side. On the dry side of the load-bearing structural component, a corresponding drive device, such as at least one actuator, for actuating, adjusting, and controlling the at least one valve can be arranged.The at least one valve is thus arranged with its medium-flowing section on the medium-carrying side of the supporting structural component and projects with its at least one mechanical drive section through the supporting structural component to its dry side, where it can be actuated, for example, via the at least one actuator. The at least one pump and the at least one actuator, on the other hand, are arranged on the dry side of the supporting structural component to prevent medium from reaching these electrical or electronic components and thus to reliably prevent short circuits.

[0010] Advantageously, the at least one valve, the at least one pump, and / or the at least one actuator, and / or the at least one sensor element can be mechanically connected to the supporting structural component by axial insertion, in particular by pushing it on and / or screwing it in, and the at least one pump, the at least one actuator, and / or the at least one sensor element can simultaneously be electrically connected in a respective end position. The latter applies to the electrically driven components, i.e., the at least one pump, the at least one actuator, and the at least one sensor element. Accordingly, it is possible to mechanically attach the at least one valve, the at least one pump, and the at least one actuator to the supporting structural component by axial insertion.When at least one pump and at least one actuator reach their respective end positions during the axial insertion process, electrical contact can be established simultaneously. This is because, in this end position, at least one electrical connection element of the pump or at least one electrical connection element of the actuator can be electrically connected to at least one electrical contact element in or on the supporting structural component. Therefore, no further electrical contacting step is required to connect the at least one pump and at least one actuator. Instead, they are electrically contacted directly in their end positions after mechanical fastening by axial insertion onto the supporting structural component. This significantly simplifies and enhances the safety of the thermal management module's assembly compared to prior art solutions.However, at least for some pumps and / or actuators and / or sensor elements, a separate electrical connection via cable and / or at least a flexible circuit board or printed circuit board may be provided. The thermal management module may therefore incorporate mechanical and / or electrical plug connections and / or electrical connections via at least a flexible circuit board / printed circuit board and / or by crimping, cold welding, and / or another contacting or connection method.

[0011] For electrical contact, the thermal management module can comprise at least one first circuit board and at least one second circuit board, the latter being provided with at least one conductor track. The first and second circuit boards are designed to be mechanically joinable and simultaneously electrically connectable. By providing at least one conductor track on the second circuit board of the thermal management module, it is possible to easily establish electrical contact between the pump and the actuator when they are attached to the dry side of the supporting structural component of the thermal management module. After axial insertion onto the dry side of the supporting structural component, for example,An electrical conductor or other electrical connection element of the at least one pump and the at least one actuator, and the at least one conductor track of the at least one second circuit board of the thermal management module, which is arranged on the dry side of the supporting structural component. Accordingly, this allows electrical contact between the at least one pump and the at least one actuator via the at least one second circuit board with its conductor tracks. By providing the at least one second circuit board with the conductor tracks applied to it, it is possible to dispense with cables or a cable harness in the thermal management module according to the invention. This thus makes it possible to avoid routing cables or a cable harness in the thermal management module to enable electrical contact between its electrical or electronic components.Electrical contact of sensor elements is also possible on at least one second circuit board with at least one conductor track applied to it.

[0012] Such a sensor element can either be electrically connected directly during mechanical assembly or be provided with at least one flexible circuit board / printed circuit board to connect the sensor element directly to the first and / or second circuit board via a connector provided on the board. The sensor element can, in particular, be part of the flexible circuit board, for example, formed as one end of it and / or embedded within it. At the other end or along the flexible circuit board, at least one connector for electrical connection to the first and / or second circuit board of the thermal management module can be arranged. For insertion into a corresponding socket on the first and / or second circuit board of the thermal management module, the flexible circuit board / printed circuit board can, in particular, have exposed or freely accessible conductor tracks at its ends.The sensor element is electrically connected by inserting the flexible circuit board into the corresponding socket. A power supply can be provided, in particular, via the first circuit board, which is designed to be mechanically and electrically connectable to the second circuit board. Accordingly, the first conductor of the second circuit board can also be electrically connected to the first circuit board, which is connected to or capable of being connected to an electrical power supply, when the two circuit boards are mechanically joined.

[0013] Furthermore, the first circuit board can be equipped with at least one electrical and / or electronic component, such as a power and / or control electronic component. In particular, it is possible to arrange at least one control unit with at least one power electronic component on the first circuit board. This enables the control of the electrical and electronic components of the thermal management module, namely the at least one valve for controlling the mass flow of at least one temperature control medium and the at least one pump for circulating the temperature control medium through the media channels of the thermal management module.

[0014] After axial mounting on the supporting structural component, the at least one pump and the at least one actuator can be electrically contacted in their respective final positions on the at least one first circuit board and / or the at least one second circuit board. For example, if several pumps are provided, at least one of them can be electrically contacted in its respective final position on the at least one first circuit board when axially mounted on the dry side of the supporting structural component, while the remaining pumps and, for example, the at least one actuator are electrically contacted in their respective final positions on the at least one second circuit board when axially mounted on the dry side of the supporting structural component.

[0015] Advantageously, at least one electrical and / or electronic component, in particular the at least one actuator and the at least one pump, at least one mechanical component, and at least one cooling module for cooling the electronic and / or electrical component(s) can be arranged on the dry side of the load-bearing structural component. Furthermore, the at least one electrical and / or electronic component, in particular a power and / or control electronic component, arranged on the at least one first circuit board, can be cooled by the at least one cooling module, wherein the at least one cooling module is arranged on or above the at least one electrical and / or electronic component, in particular a power and control electronic component.The cooling module can be positioned directly where it is needed to cool the electrical and / or electronic components that generate a particularly high amount of heat, especially power and / or control electronic components. It is especially advantageous for at least one cooling module in a battery-electric vehicle to be arranged with airflow, thus enabling optimal cooling of the electrical and / or electronic components, particularly the power or control electronic components. In a battery-electric vehicle with at least one air-cooled radiator, the thermal management module can be located on or in the vicinity of this air-cooled radiator.In particular, it is advantageous to arrange the thermal management module, with its at least one cooling module, in the battery-electric vehicle above or at the upper edge of the at least one air-permeable radiator of the battery-electric vehicle, or on the at least one air-permeable radiator itself. This allows both the air-permeable radiator of the battery-electric vehicle and the at least one cooling module located on the dry side of the supporting structural component of the thermal management module to be permeable to air, and thus, primarily, to the airflow during driving, in the front area of ​​the vehicle. The thermal management module can also be used in a hybrid vehicle.

[0016] The thermal management module can further comprise at least one first covering device for form-fittingly covering the dry side and at least one second covering device for covering the media-carrying side of the load-bearing structural component. In particular, it is also possible to provide only the second covering device if covering the dry side of the load-bearing structural component does not appear necessary. Partial covering of the dry side of the load-bearing structural component is also possible. The first covering device can have at least one opening for the passage of at least one cooling module arranged on the dry side of the load-bearing structural component of the thermal management module.This makes it possible to protect all components located on the dry side of the load-bearing structural component of the thermal management module from the ingress of dirt and moisture by means of at least one initial cover device. Only the at least one cooling module protrudes through the at least one opening in the initial cover device to allow cooling air to flow around it. At least one seal can be provided in the area of ​​the at least one opening for the passage of the at least one cooling module to reliably prevent the ingress of dirt, dust, or moisture into the area of ​​the at least one cooling module. The form-fitting cover of the components located on the dry side of the load-bearing structural component of the thermal management module allows for space-saving concealment of these components.The first cover protects the at least one pump and the at least one actuator from external elements. To improve cooling, particularly of the at least one pump, a section of its cylindrical pump body can protrude from the first cover, while the remaining section is protected beneath the cover.

[0017] Advantageously, at least one second cover device can be provided with second partial profiles of media channels for closing the first partial profiles of media channels arranged on the supporting structural component and completing the media channels of the thermal management module. Advantageously, the second cover device can also include grid-like sections, allowing airflow through these areas and thus enabling cooling of the media channels. Furthermore, the second cover device can include connection points for connecting media lines to the thermal management module for supplying and discharging temperature control media, such as coolant.The connection ports for media lines, located on the second cover, can be positioned, in particular, facing away from the supporting structural component on which the second cover is mounted, thus on the side of the second cover facing away from the supporting structural component. This allows for very good connection of media lines to these ports, as they are easily accessible, especially when the thermal management module is located on the top or upper edge of an air-cooled radiator of a battery-electric vehicle. The supporting structural component can also be provided with at least one connection port located at its edge, in fluid contact with the media channels or initial sections of media channels.Media lines for supplying and removing temperature control media, such as coolant, can also be connected to these connection ports for flowing through the media paths of the supporting structural component of the thermal management module.

[0018] The connection ports of the thermal management module for connecting media lines can thus be arranged on the rear side and / or underside of the thermal management module, facing away from the air-cooled radiator of the battery-electric vehicle. The connection ports located on the underside of the thermal management module are those located on the supporting structural component. All connection ports of the second cover for covering the media-carrying side of the supporting structural component are therefore arranged facing away from the air-cooled radiator of a vehicle, in order to enable particularly simple and safe connection of media lines to the connection ports and to avoid disrupting the airflow through the air-cooled radiator. The thermal management module, and in particular its supporting structural component, can further advantageously include at least one flap valve or...The system must include a check valve along at least one of its media paths. This check valve, or flap valve, can be located in a first section of a media path within the supporting structural component, or in a second section of the media path within the second cover device for covering the media-carrying side of the supporting structural component. The flap valve, designed as a check valve, serves to restrict the flow direction of the medium within the media paths of the thermal management module, thus preventing backflow of the medium in an undesired direction. This makes it possible to prevent unwanted coupling of different circuits within the thermal management module in various operating modes.

[0019] A further objective underlying the present invention is to minimize the number of actuators required to drive the at least two valves. This can be achieved by using one actuator and at least one gear structure to jointly control several valves, wherein the actuator and the valves are connectable to or connected to the at least one gear structure.

[0020] This makes it possible to adjust or actuate at least two valves for controlling mass flows of at least one temperature control medium using only one actuator and at least one gear structure. This reduces the number of actuators required to operate these valves to one for all of them, instead of the usual single actuator for each valve. This is cost-effective compared to using a separate actuator for each valve. Furthermore, it may also reduce the number of components mounted on the supporting structural element of the thermal management module. However, the gear structure does require additional components compared to a design without it. The gear structure can advantageously include at least one rack, which is operatively connected to the actuator and the valves.Such a functional connection can be established, for example, via gears, whereby the valves and the actuator are operatively connected to the at least one rack via such gears. In particular, it is possible to provide at least one drive shaft of each valve and at least one output shaft of the actuator with at least one gear each. The gears can mesh with the teeth of the respective rack in the load-bearing structural component of the thermal management module. Depending on the number of valves to be driven via the gear structure, in particular the at least one rack, three interconnectable or connected racks can, for example, be provided, wherein the actuator is operatively connected to one of the three racks and the valves are operatively connected to the other two racks.This allows for a particularly optimal arrangement of the actuator and valves within the load-bearing structural component. For example, the actuator can engage the gear of at least one rack in a central region along its length, while the valves engage the rack outside this central region. If the aforementioned three racks are provided, the actuator can engage a central rack located between two outer racks, and the valves can engage the two outer racks positioned laterally to the central rack, with the central rack being connected to the two outer racks. The three racks can be aligned or offset from one another.With an offset arrangement, it is particularly possible to position the middle rack offset from the two outer racks. This allows for compensation of manufacturing tolerances in the supporting structural component.

[0021] By moving the central rack, the actuator can also move the outer racks connected to it, thereby actuating the valves operatively connected to these outer racks. All these valves are actuated simultaneously. However, not all valves necessarily switch at the same time. For example, a partial rotation of a valve may not move it from a closed or open position. This can be controlled or regulated by the passages and surfaces of the valve's rotating bodies in relation to the rack movement. To ensure proper positioning of the valves, their gears, and the racks, the gears and racks can have markings that are aligned with each other, thus facilitating correct positioning. Additional valves can also be connected to the thermal management module or...whose supporting structural component is arranged, which are actuated by further actuators, unless these are to be actuated simultaneously with the valves that can be actuated by the one actuator and the transmission structure.

[0022] As mentioned above, the provision of three racks is particularly suitable for compensating for manufacturing tolerances. Since the gears and racks are fixedly arranged on the load-bearing structural component, especially its dry side, but manufacturing tolerances due to distortion can occur during the production of the load-bearing structural component, the provision of three racks proves advantageous. Furthermore, the thermal management module can advantageously include at least one tolerance compensation device for compensating for tolerances in the positioning of the valves on the at least one load-bearing structural component, in particular a floating bearing of the valves being provided as a tolerance compensation device.This makes it possible, in particular, to compensate for distortions during the manufacturing of the load-bearing structural component and the resulting manufacturing tolerances by means of such a tolerance compensation device, especially in the form of a floating bearing for the valves. Such a floating bearing allows for adjustment of the valves' relative positions and a reduction of angular misalignment between the valves, thus enabling optimal engagement of the gears connected to the valve drive shafts with the racks. Centering of the valves with respect to their drive shafts, which engage with and are fixed in the gears, is possible from the medium-flow side of the load-bearing structural component. Valve inserts or similar components can be used for the floating bearing of the valves.The valve pistons are housed in valve pots sealed to the respective valve drive shafts, and the valve pots are arranged within the supporting structural component with some play. A centering seat can be provided within the respective valve pot in the upper and lower regions of the valve insert or valve piston. For sealing the valve pots, for example, a molded seal can be provided in the direction of the respective valve's drive shaft, or a shaft seal or O-ring can be used in conjunction with a shaft seal.

[0023] Especially with large injection-molded components, maintaining tight manufacturing tolerances is challenging due to warpage. The load-bearing structural component is one such large injection-molded part, where high accuracy requirements exist, particularly regarding the geometry of the valve mounting contours. For example, the general tolerances for the center-to-center distance between two valves according to ISO 20457-TG6 are approximately 400 mm ± 1.15 mm. Therefore, it has been shown that the position of the valves relative to the rack and pinion valve train, its racks, and the respective through-hole of each valve piston shaft or drive shaft must be very precise, with a positional tolerance significantly lower than the center-to-center distance tolerance of the valve piston shafts or drive shafts, for example, a positional tolerance of ± 0.2 mm.Therefore, to precisely position the valves in the valve receptacles of the supporting structural component, the respective valve receptacle can advantageously have at least one calibration element on its inner surface facing the valve to be received or already received therein, and the valve body of the respective valve can be provided on its outer wall with at least one receiving element for receiving the at least one calibration element. When a respective valve body is inserted into a respective valve receptacle, the at least one calibration element and the at least one receiving element advantageously engage with each other. The positioning of the calibration elements on the inner surface of the respective valve receptacle can be finely adjusted or set in the injection mold during the production of the supporting structural component. At least one valve piston is received in the valve body of a valve.This component, with its drive shaft, extends through the corresponding through-opening in the supporting structural component from its fluid-carrying side to its dry side. By providing at least one calibration element on the respective valve receptacle and at least one receiving element on the respective valve body of each valve, it is possible to precisely position the valve body within the receptacle. This also allows for fine-tuning of the valve piston within the through-opening in the supporting structural component of the thermal management module. The at least one calibration element can be designed as a rib projecting into the interior of the respective valve receptacle, and the at least one receiving element, arranged on the outer wall of the respective valve body, can be designed as two spaced-apart, parallel, outwardly projecting ribs.The latter can be spaced such that they can accommodate, or do accommodate, the respective calibration element between them. This allows the valve pot to be guided when inserted into the valve receptacle, as soon as the respective calibration element, designed as a bridge, engages between the two bridges of the receptacle element.

[0024] The present invention further solves the problem of enabling simpler control of the components of the thermal management module. This is achieved by centrally arranging at least one control unit with at least one power electronics component for controlling the electrical and electronic components to be controlled within the thermal management module, and by centrally arranging at least one cooling module for cooling the control unit with the at least one power electronics component within the thermal management module. This makes it possible to directly control the electrical and electronic components of the thermal management module via the at least one control unit with the at least one power electronics component, since the at least one control unit and the at least one power electronics component are centrally arranged together within the thermal management module.Furthermore, cooling of the heat-generating control unit and the at least one power electronics component is possible via the at least one cooling module, which is also centrally located within the thermal management module. The at least one cooling module can, for example, be designed as a finned radiator and positioned to allow airflow within a battery-electric vehicle. This can be achieved by arranging the thermal management module on or in the area of ​​an air-permeable radiator of the battery-electric vehicle. Both the air-permeable radiator of the battery-electric vehicle and the cooling module for cooling the at least one control unit with the at least one power electronics component can be exposed to airflow. This allows for very efficient heat dissipation via the cooling module, particularly a finned radiator.

[0025] The at least one control unit can also serve to directly control the electrical and / or electronic components to be controlled electronically. The mechanical control is advantageously achieved via the at least one actuator, which is controlled accordingly by the at least one control unit, so that one or more valves can be actuated by the at least one actuator. For example, pumps can be directly controlled electronically by the at least one control unit. In principle, it is possible to equip one or more actuators with their own control unit(s).

[0026] To explain the invention in more detail, exemplary embodiments are described below with reference to the drawings. These show, in Figure 1, a perspective view of an air-flowing radiator of a vehicle with a thermal management module according to the invention arranged on its upper side.

[0027] Figure 2 shows a perspective rear view of the air-flowable cooler equipped with the thermal management module according to the invention.

[0028] Figure 3 shows a perspective front view of the thermal management module according to Figure 1.

[0029] Figure 4 shows a perspective rear view of the thermal management module according to Figure 2 or Figure 3.

[0030] Figure 5 shows a perspective exploded view of the thermal management module according to Figures 3 and 4.

[0031] Figure 6a shows a perspective view of a second cover device of the thermal management module according to the invention as shown in Figure 3, with a view of its partial profiles of media paths,

[0032] Figure 6b shows a perspective view of the second cover device according to Figure 6a, looking towards its connection nozzle.

[0033] Figure 7a shows a perspective view of a load-bearing structural component of the thermal management module according to Figure 3, looking towards the dry side of the portable structural component according to the invention.

[0034] Figure 7b shows a perspective view of the load-bearing structural component according to Figure 7a, looking at its media-carrying side, which is opposite the dry side and which is provided with partial profiles of media channels.

[0035] Figure 8a shows a perspective front view of a first covering device according to the invention for the thermal management module according to Figure 3 for covering the dry side of its supporting structural component,

[0036] Figure 8b shows a perspective rear view of the first covering device according to Figure 8a,

[0037] Figure 9a shows a top view of the dry side of a load-bearing structural component of the thermal management module according to the invention as shown in Figure 3 in a first embodiment of an actuator driving several valves with a gear structure; Figure 9b shows a top view of the dry side of a load-bearing structural component of the thermal management module according to the invention as shown in Figure 3 in a second embodiment of an actuator driving several valves with a gear structure.

[0038] Figure 10 shows a detailed view of the supporting structural component of the thermal management module according to Figure 9b in the area of ​​the actuator driving several valves, whose gear engages in a central rack,

[0039] Figure 11a shows a perspective view of a gear structure according to the invention for driving four valves of the thermal management module according to Figure 3.

[0040] Figure 11b shows a perspective exploded view of a second embodiment of a gear structure according to the invention for driving four valves of the thermal management module according to Figure 3.

[0041] Figure 11c shows a perspective exploded view of the gear structure according to Figure 11a.

[0042] Figure 12 shows a top view of the media-carrying side of the supporting structural component of the thermal management module according to Figure 3, which is provided with the second cover device.

[0043] Figure 13 shows a top view of the media-carrying side of the supporting structural component of the thermal management module according to Figure 3 with the second cover device removed from it.

[0044] Figure 14 shows a perspective detail view of a section of a media path on the media-carrying side of the supporting structural component according to Figure 13 in the area marked D, wherein a flap valve according to the invention is arranged in the media path in this area.

[0045] Figure 15 shows a top view of the section of the media path on the media-carrying side of the supporting structural component, which is provided with the flap valve according to Figure 14.

[0046] Figure 16 shows a longitudinal section view along line AA from Figure 15 through the media path in the area of ​​the flap valve; Figure 17 shows a perspective view of an arrangement according to the invention of three circuit boards according to the invention with pumps, actuators and sensor elements arranged thereon;

[0047] Figure 18 shows a perspective view of the three circuit boards according to Figure 17 before they are joined together,

[0048] Figure 18a shows a perspective view of the three circuit boards according to Figure 17 after they have been joined together.

[0049] Figure 19a shows a perspective detail view of the arrangement according to Figure 17 in the area of ​​a pump, an actuator and a sensor element,

[0050] Figure 19b shows a perspective view of the arrangement according to Figure 17 in the area of ​​a sensor element,

[0051] Figure 20 shows a perspective top view of the media-carrying side of a further embodiment of a load-bearing structural component of the thermal management module according to Figure 3 with a second cover device removed from it.

[0052] Figure 20a shows a perspective detail view of the supporting structural component according to Figure 20 in the area of ​​a valve receptacle according to the invention, which is provided with calibration elements, and a valve pot according to the invention arranged above this, with external receiving elements for interaction with the calibration elements.

[0053] Figure 21 shows a side view of the valve receptacle freed from the rest of the supporting structural component according to Figure 20a, with the valve pot of a valve contained therein.

[0054] Figure 21a shows a sectional view of the isolated valve receptacle with the valve pot included therein, as shown in Figure 21, cut along line BB from Figure 21.

[0055] Figure 21b shows a top view of the isolated valve receptacle with the valve pot included therein according to Figure 21.

[0056] Figure 21c shows a perspective exploded view of the isolated valve mount and valve pot according to Figure 21.

[0057] Figure 22 is a top view of the media-carrying side of the supporting structural component according to Figure 20, Figure 22a is an enlarged detail view of the supporting structural component according to Figure 22 in area E, in which the valve pot of the valve is inserted into the valve receptacle of the supporting structural component,

[0058] Figure 23 shows a partial cross-sectional view of the load-bearing structural component according to Figures 20 and 22, with a view into the interior of the valves.

[0059] Figure 23a shows an enlarged detail view of the supporting structural component according to Figure 23 in the area of ​​one of the valve receptacles with a valve pot inserted therein and a valve piston arranged therein, as well as sealing elements for fluidic sealing of the valve against the valve receptacle, and

[0060] Figure 23b shows an enlarged detail view of the supporting structural component according to Figure 23 in the area of ​​a valve receptacle adjacent to the valve receptacle with valve according to Figure 23a, with a valve pot inserted therein and a valve piston arranged therein, as well as sealing elements for fluidic sealing of the valve against the valve receptacle.

[0061] Figures 1 and 2 show a thermal management module 1 arranged on an air-flow radiator 100. The thermal management module 1 is located in the upper edge region 103 of the air-flow radiator 100, which is, in particular, part of a battery-electric vehicle, on the rear side 101 of the air-flow radiator 100. The air-flow radiator 100 is positioned in a vehicle such that its front side 102 is open to airflow, such as, in particular, the airflow from a moving vehicle. The thermal management module 1, located in the upper edge region 103 of the air-flow radiator 100, comprises a cooling module 2. After the thermal management module 1 is attached to the air-flow radiator 100, this cooling module is positioned above it and can therefore also be exposed to airflow, specifically the airflow from a moving vehicle.In the embodiment shown in Figure 1, the cooling module 2 is designed as a finned radiator and, like the air-flowing radiator 100, has a direction of travel F (see arrow) of a vehicle, which, however, is not visible in Figures 1 and 2. The airflow striking the cooling module 2 and the air-flowing radiator 100 is indicated by arrows L in Figure 1.

[0062] The cooling module 2 is enclosed in a first cover 3 of a supporting structural component 4 of the thermal management module 1. The thermal management module 1 further comprises a second cover 5 on the side of the supporting structural component 4 opposite the first cover 3. As can be seen particularly well in Figure 2, but also in the detailed views of the second cover 5 and the supporting structural component 4 in Figures 6b and 7b, the second cover 5 and the supporting structural component 4 each have connection ports for connecting media lines to the thermal management module 1. The connection ports 50 of the second cover 5 face away from the air-flowing cooler 100 on its rear side 101, making them particularly accessible for connecting media lines for supplying and discharging media to and from the thermal management module 1.The connection nozzles 40 are arranged on the underside 41 of the supporting structural component 4, so that they are also easily accessible from the rear 101 of the air-flowing cooler 100, since no other components of a vehicle are arranged on this rear 101 of the air-flowing cooler 100, thus providing space for connecting media lines to the supporting structural component 4 of the thermal management module 1.

[0063] The thermal management module 1, without the air-flow cooler 100, can be seen in Figures 3 and 4. These figures, as well as the exploded view of the thermal management module 1 in Figure 5, clearly show its three-layered structure, including the supporting structural component 4 as the middle layer and the two cover devices 3 and 5. As can be seen particularly well in Figure 7a, the supporting structural component 4 has a dry side 42 and, on the opposite side (which can be seen particularly well in Figure 7b), a media-carrying side 43. This allows for the separation of media-carrying areas of the supporting structural component from media-free areas. The media-carrying side 43 of the supporting structural component 4 is connected to media channels.The first partial profiles 44 of media channels 12 of the thermal management module 1 are provided, while electrical, electronic, and mechanical components are arranged on the dry side 42, as can be clearly seen in the exploded view of the thermal management module 1 in Figure 5. To complete the media channels 12, the second cover 5 has second partial profiles 51 of media channels, as can be seen in the perspective rear view of the second cover 5 in Figure 6a. By joining the supporting structural component 4 and the second cover 5, closed media channels 12 are created, along which temperature control media, such as coolant, can be guided through the thermal management module or its valves and pumps, as well as along sensors, such as temperature sensors.

[0064] As can also be seen in Figure 7b, the media-carrying side 43 of the supporting structural component 4 not only has the first partial profile 44 of media channels, but also receiving areas 45 for receiving components through which the medium flows, such as, in particular, valves 6 and, if applicable, sections of sensors. These are arranged with their section through which or around which the medium flows on the media-carrying side 43 of the supporting structural component 4 and project through it onto the dry side 42 of the supporting structural component 4, as do the valves 6 with their respective drive shaft 61. The respective drive shaft 61, i.e., a mechanical drive section of a respective valve 6 as a component through which the medium flows, is guided through a respective through-opening 46 of the supporting structural component 4.To reliably prevent the passage of medium from the media-carrying side 43 towards the dry side 42 of the supporting structural component 4, at least one sealing element is provided, such as a shaft seal or an O-ring in conjunction with a shaft seal. This is not shown in the figures. Pumps 7 are arranged on the dry side 42 of the supporting structural component 4. These pumps serve to convey temperature control medium into at least one temperature control circuit, particularly of a battery-electric vehicle, into which the thermal management module 1 is integrated. Accordingly, the pumps 7 serve to convey temperature control medium through the media channels 12 on the media-carrying side 43 of the supporting structural component 4 of the thermal management module 1. Valves 6, or possibly other components, are used to control the mass flow rates through the individual media channels 12 on the media-carrying side 43 of the supporting structural component 4 of the thermal management module 1.There are also further valves 8, which can also be seen in the exploded view of the thermal management module 1 in Figures 5 and 13. Actuators 9, 90, 91, 92 are provided for controlling the valves 6 and 8 and are arranged on the dry side 42 of the supporting structural component 4, as can be seen in particular in Figures 5, 9a and 9b.

[0065] For the electrical supply of the valves 6 and actuators 9, 90, 91, 92, a first circuit board 15, a second circuit board 16, and a third circuit board 17 are arranged on the dry side 42 of the supporting structural component 4. This can be seen particularly well in Figures 17, 18, and 18a. The second circuit board 16 and the third circuit board 17 comprise conductive traces and components such as sockets for electrical and mechanical connection to the pumps, actuators, and sensor elements, such as temperature sensors, as well as connectors for connecting the second and third circuit boards to the first circuit board 15. Power is supplied to the thermal management module 1 via the first circuit board 15. The first circuit board 15, the second circuit board 16, and the third circuit board 17 are thus mechanically and electrically connected to one another.In the embodiment shown in Figures 18 and 18a, the first circuit board 15 has a number of through-holes 150, and the second circuit board 16 and the third circuit board 17 each have a connector 160 or 170, respectively, whose projecting pins 161 or 171 engage in or through the through-holes 150, thus enabling a mechanical and electrical connection. Accordingly, the conductor tracks of the second circuit board 16 and the third circuit board 17 are extended to the first circuit board 15, which is centrally located in the thermal management module 1, as can be seen in Figures 18 and 18a and, for example, also in Figures 9a and 9b. At least some of the pumps 7 and actuators 9, 90, 91, 92 are electrically connected via the conductor tracks of the second circuit board 16 and the third circuit board 17. Such electrical contact is achieved, for example, wirelessly, simply by plugging or attaching and, if necessary,The pumps 7 and actuators 9, 90, 91, 92 are screwed onto the supporting structural component 4, as can be seen in Figure 17 in combination with Figures 18 and 18a. Figure 19a shows an enlarged detail of the arrangement of the pumps 7 and actuators 9, 90, 91, 92 shown in Figure 17, namely in the area of ​​the pump 7 and the actuator 92.

[0066] For example, at least one sensor element 18 can be provided which is equipped with a flexible printed circuit board 180, as can be seen particularly well in the enlarged view in Figure 19b. There, as also in Figures 17 and 19a, it is shown, for clarification that it is a flexible printed circuit board 180 which is bent over for contact and whose end is inserted into a socket 162, 172 on the respective circuit board 16, 17, once extended, i.e., in the state before insertion and contact, and once bent and its end inserted into the respective socket 162, 172 and thus contacted. At least one socket 162, 172 can be arranged on the second and / or third circuit board 16, 17, into which a plug 181 of the flexible printed circuit board 180 or the latter directly can be inserted.Figures 17, 18, and 18a show several such sockets 162 and 172 arranged by way of example on the second circuit board 16 and the third circuit board 17. A corresponding arrangement with a flexible circuit board 93 and a corresponding socket 153, 163, 173 for contacting the circuit board(s) 15, 16, 17 can be provided, for example, for at least one of the actuators 9, 90, 91, 92, as shown in Figures 17 and 18, 18a. This would allow for compensation of positional tolerances in these actuators.

[0067] The electrical connections of pumps 7 and actuators 9, 90, 91, 92, which are designed as flat contacts, are not in direct contact with the conductor tracks on circuit boards 15, 16, and 17, but are connected to the sockets 153, 163, 173 on these boards. The sockets 153, 163, 173 are arranged on circuit boards 15, 16, and 17 and are designed for connection to the flat contact connections. The connection of the sockets to the conductor tracks of circuit boards 15, 16, and 17 can be achieved by soldering or press-fit technology. In press-fit technology, an electrical connection is typically created by pressing a pin into a metallized through-hole in a circuit board and then cold-welding the connection. This creates not only an electrical connection, but also a mechanical connection between the inserted socket and the circuit board.Once each pump 7 or actuator 9, 90, 91, 92 reaches its respective end position on the supporting structural component 4, electrical contact is made between them. This can also be seen in the combination shown in Figures 17 and 18, 18a, where the pumps 7 and actuators 9, 90, 91, 92 with their electrical connections are mounted on the sockets 153, 163, 173 of the first circuit board 15, second circuit board 16 and third circuit board 17.

[0068] As can be seen particularly in Figures 9a and 9b, the cooling module 2, covering part of the first circuit board 15, is also arranged on the dry side 42 of the supporting structural component 4. The cooling module 2 covers one or more electrical or electronic components 19, such as, in particular, a power and / or control electronic component, which dissipates a large amount of heat during operation. Such electrical or electronic components 19 are shown by way of example in Figures 18 and 18a. In order to cool these components, the cooling module 2 is arranged in the area of ​​the first circuit board 15, covering them.The at least one power and / or control electronics component, in particular a control unit with a power electronics component, for controlling the electrical and electronic components to be controlled, i.e., the pumps 7 and actuators 9, 90, 91, 92, is / are thus centrally located in the thermal management module 1, possibly also in the same location as the cooling module 2 used for their cooling. The control unit with its power electronics component can directly control the pumps electronically, as well as the actuators 9, 90, 91, 92, whereby the actuators in turn mechanically control the valves 6, 8 of the thermal management module 1. The actuators, or at least some of them, can / can include their own power electronics component and control unit or intelligence. The central control unit or ECU in the thermal management module 1 can control these actuators, for example, via a bus such as a LIN bus.

[0069] As can be seen in the detailed views of the first cover assembly 3 in Figures 8a and 8b, it has a central through-opening 30 through which the cooling module 2 or its heat sink, here the fins of the finned cooler shown, can pass. To form-fitting the cover of the pumps 7 arranged adjacent to the cooling module 2 on the supporting structural component 4, the first cover assembly 3 is provided with two projecting receiving sections 31, 32 on both sides adjacent to the through-opening 30. It is also possible, in principle, to provide further through-openings here for the passage of sections of the pumps, so that these can also be cooled in the airflow.Accordingly, the cylindrical pump bodies of the respective pumps 7 can also protrude from the first cover 3 through correspondingly formed through-openings therein, whereby the respective cylindrical pump bodies are sealed against the first cover 3 in order to reliably prevent the ingress of dirt and moisture onto the dry side of the supporting structural component 4. The area of ​​the through-opening 30 is also provided with a sealing element 33 in order to reliably prevent the ingress of dirt, dust, and moisture onto the dry side 43 of the supporting structural component 4 in the area of ​​the cooling module 2 as well.

[0070] As can be seen in particular from the rear view of the first cover 3 in Figure 8b, it is also provided with a further sealing element 34 around its circumference in order to completely seal this first cover 3 against the supporting structural component 4. As can also be seen in particular from the rear view of the first cover 3 in Figure 8b, the first cover 3 has several fastening tabs 35 with fastening openings 36 in order to connect the first cover 3 to the supporting structural component 4, for example by screwing it in place. Other fastening options for the first cover 3 to the supporting structural component 4 are also possible, such as a clamping connection.

[0071] In order to enable additional cooling of the thermal management module 1 from its rear side, i.e., the side on which the second cover 5 is located, and in particular to prevent additional heat build-up there, the second cover 5 is designed as a grid in all areas that are not designed to close media passages 12 or to cover valves or pump sections. The grid-shaped sections 52 can be seen particularly well in Figures 6a and 6b.

[0072] As can be seen in particular from Figures 13 to 16, flap valves 47 can be arranged at certain points in the media channels 12 or the first partial profile 44 of media channels and / or the second partial profile 51 of media channels. These are designed as check valves and serve to prevent backflow of the temperature control medium in an unwanted direction within the media channels 12 on the media-carrying side 43 of the supporting structural component 4 or in the media channels 12 of the thermal management module 1. As can be seen in particular from Figures 14 to 16, through-openings 48, which can be opened and closed, are formed along the media channels via the respective flap valve 47, which is designed as a check valve. In the embodiment shown in Figures 14 to 16, the respective flap valve 47 and, accordingly, also the through-opening 48 in the media channel 12 are round.This can also be implemented differently in another embodiment. Furthermore, the flap valve 47 is pivotally mounted on an intermediate wall 148, which has a through-opening 48, via a pivot axis 49. This, too, can be implemented differently in another embodiment. As can be seen in Figures 9a to 11c, the valves 6 are actuated by the actuator 9. Thus, only one actuator, namely the actuator 9, is provided for actuating all four valves 6. To enable this, a gear structure 190 is provided in combination with the actuator 9. In the embodiment shown in Figures 9a, 11a and 11c, the gear structure 190 comprises three racks 191, 192, 193 arranged in alignment with each other, while in the second embodiment shown in Figures 9b and 10 and 11b, the gear structure 190 comprises racks 194, 195 and 196 offset from each other.The second rack 195 is offset from the other two racks 194 and 196 in the supporting structural component 4 on its dry side 42. To enable the connection of the respective racks 191 to 193 and 194 to 196 with the actuator 9 and the valves 6, respectively, gears 197 and 198 are provided. The gears 197 are mounted on the respective drive shafts 61 of the pumps 6, and the respective gear 198 is operatively connected to the actuator 9 at its output side. The gears 197 engage with the respective racks 191 and 193 and 194 and 196, while the respective gear 198 engages with the respective racks 192 and 195. In order to quickly and correctly position the gears and racks relative to each other, the gears 197, 198 as well as the racks 191 to 196 are provided with corresponding markings 199a and 199b respectively, as can be seen in Figures 11b and 11c.

[0073] The racks 191 to 193 and 194 to 196 are mounted in corresponding rack receptacles 200, 201, which are attached to the dry side 42 of the supporting structural component 4. Such attachment can be effected, for example, by screwing or snapping them on. The rack receptacles 200, 201 also have through-openings 202, 203 through which the respective drive shafts 61 of the valves 6 protrude. On the side 204, 205 of the two rack receptacles 200, 201 facing the racks 191, 193 and 194, 196 and the gears 197, receiving recesses 206, 207 are formed, which surround the respective through-opening 202, 203 and in which the respective gear 197 is rotatably mounted. The through-openings 202, 203 are dimensioned significantly larger than the respective drive shaft 61 of the respective valve 6 in order to allow trouble-free passage of the respective drive shaft 61 even with larger tolerances.

[0074] Since manufacturing tolerances due to warpage can occur during the production of the supporting structural component, and these tolerances can also accumulate during the assembly of the thermal management module, a tolerance compensation device is provided to compensate for tolerances in the positioning of the valves 6 on the supporting structural component 4. This device takes the form of a floating bearing for the valves. Valve pots 62, in which valve inserts or valve pistons 63 of the valves 6 are received, are arranged with clearance within the supporting structural component 4. To prevent the escape of temperature control medium from the medium-carrying side 43 towards the dry side 42 of the supporting structural component 4, the valve pots 62 are sealed to the respective drive shaft 61 of the respective valve 6. In the embodiment shown in Figure 11b, the valve pots 62 of the valves 6 are mounted on the respective rack and pinion receptacle 200.201 rearward locking mechanism. For this purpose, the valve pots 62 each have projecting locking elements 64.

[0075] The four valves 6 can thus be adjusted with respect to their relative positioning to ensure optimal movement of the gears 197 connected to them along the respective racks 191, 193 and 194, 196, even with manufacturing tolerances. Angular misalignment between the valves can also be compensated for by their floating bearings. A centering seat can be provided for the valves 6 in the lower or upper region of the respective valve insert or valve piston 63.

[0076] As can be seen in Figures 9a, 9b, and 10, the actuator 9 engages the respective second rack 192 or 195 with its gear 198. The respective second rack 192 or 195 is in contact with the two adjacent racks 191 and 193 or 194 and 196, respectively, and is either aligned with them, as shown in the embodiment according to Figure 9a, or offset from them, as shown in Figures 9b and 10. In each case, the movement of the respective second rack 192 or 195 by the gear 198 connected to the actuator 9 engages the respective first and third racks 191, 193 or 194, 196. This also engages the gears 197 connected to the respective drive shafts 61 of the valves 6, which mesh with the respective racks 191, 193 and 194, 196 respectively. This allows for adjustment of the respective media flows through the valves 6.All four valves 6 are thus adjusted simultaneously via a single actuator 9. This results in a reduced number of actuator components and therefore a smaller footprint for the entire thermal management module 1 compared to state-of-the-art solutions.

[0077] As can be seen in Figures 9a and 9b and also Figure 10 and also in the exploded view in Figure 5, the further actuators 90, 91, 92 are each operatively connected to individual valves 8 in order to be able to control them independently of the valves 6.

[0078] Especially with large injection-molded components, maintaining tight manufacturing tolerances is difficult due to warpage. The load-bearing structural component 4 is one such large injection-molded component, where high accuracy requirements exist, particularly regarding the geometry of the valve mounting contours. For example, the general tolerances for the center-to-center distance between two valves according to ISO 20457-TG6 are approximately 400 mm ± 1.15 mm. It has therefore been shown that the position of the valves 6 relative to the rack and pinion valve train or its racks 191, 193 or 194, 196 or the respective through-hole 46 of a respective valve piston shaft or drive shaft 61 of the respective valve 6 should be very precise, depending on the design with a position tolerance of significantly less than the center-to-center distance tolerance of the valve piston shafts or drive shafts 61 of the valves 6, for example with a position tolerance of ± 0.2 mm.One way of precisely positioning the valves 6 in valve receptacles 141 of the supporting structural component 4 is shown in Figures 20 to 22a. As can be seen from these figures, calibration elements 140 are provided in the valve receptacles 141 in the supporting structural component 4 in conjunction with a valve pot 65 that accommodates a valve piston 66 (shown in Figures 23, 23a, 23b). The valve pot 65 has receiving elements 67 on its outer wall 265 for receiving the calibration elements 140. This allows for fine centering of the valve piston 66. The positioning of the calibration elements 140, which are arranged on the inner surface 142 of the respective valve receptacle 141 facing the valve pot 65, can be finely adjusted in the injection mold during the production of the supporting structural component 4.The calibration elements 140 are shown in Figures 20 to 22a as webs projecting into the interior of the valve receptacles 141, and the receiving elements 67 arranged on the outer side of the respective outer wall 265 of the valve pots 65 are designed as two spaced-apart, parallel, outwardly projecting webs that are spaced apart from each other such that they can accommodate, or do accommodate, the respective calibration element 140 between them. Thus, the valve pots 65 can be inserted into the valve receptacles 141, with the calibration elements 140 engaging the receiving elements 67 providing guidance during the insertion process. The valve pots 65 can therefore be positioned very precisely within the valve receptacles 141 in the supporting structural component 4.

[0079] Figures 21 to 21c show, on the one hand, one of the valve receptacles 141 of the supporting structural component 4 from Figures 20 and 20a in isolation, i.e., isolated from the supporting structural component 4, and on the other hand, the valve housing 65. As can be seen particularly in the sectional view in Figure 21a, a very precise geometry of the valve receptacle 141 is possible. Furthermore, any potential distortion of the valve housing 65 can be kept much smaller than any potential distortion of the supporting structural component 4 as a whole.By providing the receiving elements 67 arranged on the outer wall 265 of the valve pot 65 in combination with the calibration elements 140 in the respective valve receptacle 141 of the supporting structural component 4, local geometric properties such as roundness, cylindricity, flatness, and coaxiality, which are required for the valve function and in particular the sealing function of the valve 6 in the area of ​​the drive shaft 61 of its valve piston 66 against the through-opening 46 in the supporting structural component 4, can be achieved. This enables the integration of valves 6 into the supporting structural component 4 as a large injection-molded part.

[0080] Figures 22 and 23 show a top view of the media-carrying side 43 of the supporting structural component 4 according to Figure 20, with one of the valve receptacles 141 with the valve pot 65 arranged therein shown as an enlarged detail in Figure 22a. In the sectional views of Figure 23 and especially Figures 23a and 23b, the respective valve pistons 66 within the valve pots 65 and sealing elements 68 as valve seals for sealing the valves 6 against the valve receptacles 141 of the supporting structural component 4 can be seen. The sealing elements 68 are arranged at the transition to the media channels 12 to ensure sufficient sealing of the valve pots 65 against the respective valve receptacle 141 in the area of ​​the transition to the respective media channel 12 and thus to prevent unwanted internal leakage between the media channels 12.A seal in the direction of the dry side 42 of the load-bearing structural component 4 can be achieved by a sealing element which is inserted into the passage opening 46, see in particular Figure 20a, or arranged around it, in particular on a step provided there.

[0081] In Figure 23b, the valve pot 65 in the valve receptacle 141 of the valve 6 is shown enlarged from the detail view in Figure 20a with valve piston 66 and sealing elements 68, while in Figure 23a the valve pot 65 in the valve receptacle 141 from Figures 21 to 21c is shown enlarged together with valve piston 66 and sealing elements 68. These valves 6 differ in that, in the valves 6 according to figures 20a and 23b, three openings 69 oriented approximately at right angles to each other are formed in the respective outer wall 265 of the valve pot 65 for the inflow and outflow of medium, whereas in the valves 6 according to figures 21 to 21c and 23a, two of the three openings 69 in the outer wall 265 of the valve pot 65 are close to each other and one opening 69 is positioned approximately in line with one of the other two openings 69.Accordingly, the valve piston 66 of the valve 6 according to figures 20a and 23b also differs from that of the valve 6 according to figures 21 to 21c and 23a.

[0082] By providing circuit boards 15, 16, and 17, short paths for the main electronic components of the thermal management module 1 and direct contact between them on circuit boards 15, 16, and 17 can be ensured. This proves particularly advantageous because the provision of conductor tracks on the second and third circuit boards 16 and 17 eliminates the need for a wiring harness. Through suitable routing of the conductor tracks on the two circuit boards 16 and 17, as well as on circuit board 15, all electrical and electronic components of the thermal management module can be optimally electrically contacted and supplied with an electrical current.

[0083] The three circuit boards 15, 16, 17 are simply plugged onto the dry side 42 of the supporting structural component and are thus already electrically connected to each other.

[0084] The remaining components of the thermal management module 1 can also be mechanically connected to the supporting structural component 4 simply by axially inserting them onto it. If necessary, they can also be electrically connected to the circuit boards 15 to 17 simultaneously once they reach their respective final positions. As explained above with regard to any sensor elements and actuators, it is also possible to equip one or more of the components of the thermal management module with at least one flexible printed circuit board and to arrange at least one corresponding socket for electrical connection on at least one of the circuit boards 15, 16, or 17. Thus, the mechanical and electrical connections are not made in a single assembly step. The electrical connection on the circuit board(s) 15, 16, or 17 is made separately from the mechanical connection.This allows for simple assembly of the individual components of the thermal management module onto its supporting structural component 4. The dry side 42 of the supporting structural component 4 can already be provided with one or more rack mounts for receiving the racks 191 to 196 of the gear structure 190 for driving the valves 6 via the actuator 9, or can be provided with corresponding rack mounts 200, 201 by joining them. Since the gears 197 are also simply pushed onto the drive shafts 61 of the valves 6, simple and quick assembly is also possible for these. The same applies to the gear 198 and the actuator 9. The two cover devices 3 and 5 can also be easily connected to the supporting structural component 4 of the thermal management module 1, in particular by screw or plug connections.On the media-carrying side 43 of the supporting structural component 4, joining it with the second cover device 5 enables the completion and corresponding closure of the media paths 12. Media lines (not shown in the figures) for supplying and discharging temperature control medium to and from the thermal management module 1 can be connected via the connection ports 50 provided in the second cover device 5 and the connection ports 40 located at the edge of the supporting structural component 4. This is easily accomplished due to the simple accessibility from the rear and underside of the thermal management module 1. The thermal management module 1 can either be arranged independently in a vehicle, such as a battery-electric vehicle, or, as shown in Figures 1 and 2, in the upper edge region 103 of the air-flowable radiator 100 of a vehicle, such as a battery-electric vehicle.This position facilitates the direct flow of cooling air around the cooling module 2, which cools at least one power electronics component or a control unit with a power electronics component. These components are centrally located on the dry side 43 of the supporting structural component 4 of the thermal management module 1 on the first circuit board 15. This enables simple and effective cooling of the control unit and power electronics components of the thermal management module 1. Therefore, aligning the cooling module 2 adjacent to the airflow of the air-permeable cooler 100 is advantageous for cooling the power electronics components of the thermal management module 1.

[0085] In addition to the embodiment variants of a thermal management module described above and shown in the figures, which comprises a supporting structural component, media channels, at least one valve, at least one pump and at least one actuator, numerous other versions can be formed, in each of which the supporting structural component serves to separate areas through which the medium flows and areas without medium flows, and has a media-carrying side with media channels or parts thereof and a dry side opposite the media-carrying side with electrical, electronic and mechanical components arranged or arrangable there.

[0086] Reference symbol list

[0087] 1 Thermal management module

[0088] 2 Cooling module

[0089] 3 first covering device

[0090] 4 load-bearing structural component

[0091] 5 second cover device

[0092] 6 valve

[0093] 7 Pump

[0094] 8 valve

[0095] 9 Actuator

[0096] 10 Front

[0097] 11 Back

[0098] 12 Media pathway

[0099] 13 Underside

[0100] 15 first circuit board

[0101] 16 second circuit board

[0102] 17 third circuit board

[0103] 18 sensor elements

[0104] 19 electrical / electronic components

[0105] 30 Passage opening

[0106] 31 projecting recording section

[0107] 32 projecting recording section

[0108] 33 Sealing element

[0109] 34 Sealing element

[0110] 35 Mounting tab

[0111] 36 Mounting opening

[0112] 40 connection spigots

[0113] 41 Underside

[0114] 42 Dry side

[0115] 43 media-leading page

[0116] 44 first sub-profile of media routes

[0117] 45 recording area

[0118] 46 Through opening flap valve

[0119] Passage opening

[0120] Joint axle

[0121] Connection nozzle, second partial profile of media paths, grid-shaped section, media-flowable section

[0122] drive shaft

[0123] Valve pot

[0124] Valve insert / valve piston

[0125] Latching element

[0126] Valve pot

[0127] Valve piston

[0128] Recording element

[0129] Sealing element

[0130] opening

[0131] actuator

[0132] actuator

[0133] Actuator flexible circuit board / printed board airflow cooler back

[0134] front upper edge area

[0135] Calibration element

[0136] Valve mount

[0137] inside

[0138] partition wall

[0139] Passage opening

[0140] socket

[0141] Plug

[0142] Pen

[0143] socket

[0144] Socket 70, plug 71, pin 72, socket 73, socket 80, flexible circuit board / PCB

[0145] 181 plugs

[0146] 190 Gearbox structure

[0147] 191 first rack

[0148] 192 second rack

[0149] 193 third rack

[0150] 194 first rack

[0151] 195 second rack

[0152] 196 third rack

[0153] 197 gear

[0154] 198 gear

[0155] 199a Marking on the gear

[0156] 199b Marking on rack

[0157] 200 first rack mounting

[0158] 201 second rack mount

[0159] 202 Passage opening

[0160] 203 Passage opening

[0161] Page 204

[0162] Page 205

[0163] 206 Intake depth

[0164] 207 In-depth recording

[0165] 265 Outer wall of 65

[0166] F Direction of travel

[0167] L Airflow

Claims

Claims 1. Thermal management module (1) comprising a load-bearing structural component (4), media channels (12), at least one valve (6, 8) for controlling mass flows of at least one temperature control medium along at least one media channel (12), at least one pump (7) for conveying temperature control medium along at least one media channel (12), at least one actuator (9, 90, 91, 92) for opening and adjusting the at least one valve (6, 8), and at least one sensor element (18), characterized in that the load-bearing structural component (4) serves to separate media-flow areas and non-media-flow areas and comprises a media-carrying side (43) with media channels (12) or first partial profiles (44) of media channels (12) and a dry side (42) opposite the media-carrying side (43) with electrical and / or electronic and / or mechanical components (6, 7, 8, 9) that can be arranged on or in it. 19, 90, 91, 92, 190).

2. Thermal management module (1) according to claim 1, characterized in that the supporting structural component (4) comprises at least one through-opening (46) for the passage of at least one mechanical drive section (61) of a media-flowable component, in particular at least one valve (6), from the media-carrying side (43) of the supporting structural component (4) to its dry side (42), wherein a seal of the media-flowable component, in particular of the at least one valve (6), is provided on the media-carrying side (43) of the supporting structural component (4).

3. Thermal management module (1) according to claim 1 or 2, characterized in that the at least one valve (6, 8), the at least one pump (7) and / or the at least one actuator (9, 90, 91, 92) and / or the at least one sensor element on the supporting structural component (4) are axially The components are mechanically connectable or connected to the supporting structural component (4), in particular by attaching and / or screwing in, and the at least one pump (7) and / or the at least one actuator (9, 90, 91, 92) and / or the at least one sensor element (18) are simultaneously electrically contactable or connected in a respective end position.

4. Thermal management module (1) according to one of the preceding claims or according to the preamble of claim 1, characterized in that the thermal management module (1) comprises at least one first circuit board (15), in particular at least one first circuit board with at least one electrical and / or electronic component (19), in particular a power and / or control electronic component, and at least one second circuit board (16, 17) provided with at least one conductor track, wherein the at least one first circuit board (15) and the at least one second circuit board (16, 17) are mechanically joinable or joined to one another and are simultaneously electrically connectable or connected to one another.

5. Thermal management module (1 ) according to claim 4, characterized in that the at least one pump (7) and the at least one actuator (9, 90, 91 , 92) are electrically contactable or contacted on the at least one first and / or second and / or third circuit board (15, 16, 17) when axially mounted on the supporting structural component (4) in a respective end position.

6. Thermal management module (1) according to one of the preceding claims, characterized in that at least one electrical and / or electronic component, in particular the at least one actuator (9, 90, 91, 92) and the at least one pump (7), at least one mechanical component (190) and at least one cooling module (2) for cooling at least one electronic and / or electrical component are arranged on the dry side (42) of the supporting structural component (4).

7. Thermal management module (1) according to claim 6, characterized in that the at least one electrical and / or electronic component (19), in particular a power and / or control electronic component, arranged on the at least one first circuit board (15), can be cooled by the at least one cooling module (2), wherein the at least one cooling module (2) can be arranged or is arranged on or above the at least one electrical and / or electronic component (19), in particular a power and / or control electronic component.

8. Thermal management module (1 ) according to one of the preceding claims, characterized in that the thermal management module (1 ) comprises at least a first covering device (3) for form-fitting covering of the dry side (42) and at least a second covering device (5) for covering the media-carrying side (43) of the supporting structural component (4).

9. Thermal management module (1 ) according to claim 8, characterized in that the first cover device (3) has at least one through-opening (30) for the passage of at least one cooling module (2) arranged on the dry side (42) of the supporting structural component (4) of the thermal management module (1 ).

10. Thermal management module (1 ) according to claim 8 or 9, characterized in that the second cover device (5) is provided with second partial profiles (51 ) of media channels (12) for closing the first partial profiles (44) of media channels (12) and completing the media channels (12) of the supporting structural component (4) of the thermal management module (1 ).

11. Thermal management module (1) according to claim 8, 9 or 10, characterized in that the second covering device (5) comprises grid-shaped sections (52).

12. Thermal management module (1 ) according to one of claims 8 to 11 , characterized in that the second cover device (5) comprises connection ports (50) for connecting media lines to the thermal management module (1 ).

13. Thermal management module (1 ) according to one of the preceding claims, characterized in that the supporting structural component (4) is provided with at least one connection nozzle (40) arranged at the edge of the supporting structural component (4) which is in fluid communication with the media paths (12) or first partial profiles (44) of media paths (12).

14. Thermal management module (1 ) according to one of the preceding claims, characterized in that the thermal management module (1 ), in particular its supporting structural component (4), comprises at least one flap valve (48) along at least one of its media paths (12) or its first partial profiles (44) of media paths (12).

15. Thermal management module (1) comprising at least one load-bearing structural component (4), at least two valves (6) for controlling mass flows of at least one temperature control medium and at least two pumps (7) for conveying temperature control medium in at least one temperature control circuit of a battery electric vehicle, characterized in that an actuator (9) and at least one transmission structure (190) serve to jointly control several valves (6), wherein the actuator (9) and the valves (6) are connectable or connected to the at least one transmission structure (190).

16. Thermal management module (1) according to claim 15, characterized in that comprising at least one gear structure (190) comprising at least one rack (191, 192, 193, 194, 195, 196), in particular three racks (191, 192, 193, 194, 195, 196) that can be connected or linked together, wherein the at least one rack (191, 192, 193, 194, 195, 196) is operatively connected to the actuator (9) and the valves (6).

17. Thermal management module (1 ) according to claim 15 or 16, characterized in that the valves (6) and the actuator (9) are operatively connected to the at least one rack (191 , 192, 193, 194, 195, 196) via gears (197, 198), in particular at least one drive shaft (61 ) of a respective valve (6) and at least one output of the actuator (9) can each be provided with or equipped with at least one gear (197, 198).

18. Thermal management module (1) according to one of claims 15 to 17, characterized in that the actuator (9) engages with its gear (198) in a central region with respect to the longitudinal extent of the at least one rack (191, 192, 193, 194, 195, 196) or of a central rack (192, 195) arranged between two outer racks (191, 193, 194, 196) and the valves (6) engage outside the central region on the at least one rack or on the outer racks (191, 193, 194, 196).

19. Thermal management module (1 ) according to one of claims 15 to 18, characterized in that the thermal management module (1 ) comprises at least one tolerance compensation device for compensating tolerances in the area of ​​the positioning of the valves (6) on the at least one supporting structural component (4), in particular a floating bearing of the valves (6) is provided as a tolerance compensation device.

20. Thermal management module (1) according to claim 19, characterized in that For the floating mounting of the valves (6), valve inserts or valve pistons (63) of the valves (6) are received in valve pots (62) sealed to the respective drive shaft (61) of the valves (6) and the valve pots (62) are arranged with freedom of movement in the supporting structural component (4).

21. Thermal management module (1) according to claim 19, characterized in that, for the precise positioning of the valves (6) in valve receptacles (141) of the supporting structural component (4), the respective valve receptacle (141) has at least one calibration element (140) on its inner side (142) facing the valve (6) to be received or received therein, and a valve pot (65) of the respective valve (6) is provided on its outer wall (265) with at least one receiving element (67) for receiving the at least one calibration element (140).

22. Thermal management module (1) comprising electrical and electronic components to be controlled, in particular at least one actuator (9, 90, 91, 92) for electrically controlling at least two valves (6, 8) for controlling mass flows of at least one temperature control medium and at least two pumps (7) for conveying temperature control medium, characterized in that at least one control device with at least one power electronics component for controlling the electrical and electronic components to be controlled is arranged centrally in the thermal management module (1) and at least one cooling module (2) for cooling the control device with the at least one power electronics component is arranged centrally in the thermal management module (1).

23. Thermal management module (1) according to claim 22, characterized in that which includes at least one control device for the direct electronic control of the electrical and / or electronic components to be controlled.

24. Battery electric vehicle with at least one air-flowable cooler (100) and at least one thermal management module, characterized in that the at least one thermal management module is a thermal management module (1 ) according to one of the preceding claims, which is arranged on or in the area of ​​the air-flowable cooler.

25. Battery-electric vehicle according to claim 24, characterized in that Connection ports (40, 50) of the thermal management module (1 ) for connecting media lines with respect to the air-flowable cooler (100) are arranged on the rear side (11 ) and / or underside (13) of the thermal management module (1 ) facing away from the air-flowable cooler (100).

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