Integrated Battery Thermal Module With In-Channel Heating
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Solution Overview
Problem
Existing thermal management modules for battery packs in vehicles are complex, costly, and require significant installation space due to their numerous individual components.
Innovation Solution
A thermal management module comprising a fluid channel made of two or three plastic components, a fluid pump fixed to the channel, and a heating element arranged within the channel, allowing for efficient cooling and heating of the battery pack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If thermal management modules use many individual components for cooling and heating, then thermal management functionality is comprehensive, but device complexity increases and manufacturing costs rise
Solution Approach 1:
The patent combines cooling channels and heating elements into a single integrated fluid channel structure. The fluid channel contains both cooling passages and heating elements (resistive heating wires or PTC heaters) within the same component, eliminating the need for separate cooling and heating systems. This merging reduces component count while maintaining comprehensive thermal management capability.
Solution Approach 2:
The fluid channel serves multiple functions simultaneously: it acts as a cooling passage for coolant flow, a heating element support structure, and a structural component of the thermal management module. The same fluid channel structure provides both cooling and heating capabilities, making it a multi-functional component that reduces overall system complexity.
2Adaptability or versatility
If thermal management modules include many individual components, then thermal control capabilities are comprehensive, but installation space requirements increase
Solution Approach 1:
By merging cooling channels and heating elements into a single integrated fluid channel, the patent reduces the total volume required for thermal management components. The co-location of cooling and heating functions within the same spatial envelope eliminates the need for separate component volumes, thereby reducing installation space requirements.
Solution Approach 2:
The heating elements are nested within the fluid channel structure, with resistive heating wires or PTC heaters positioned inside the cooling passages. This nesting arrangement allows heating and cooling functions to occupy the same spatial volume, maximizing space utilization and reducing overall installation requirements.
3Adaptability or versatility
If thermal management modules use many individual components, then thermal management functions are complete, but assembly complexity and manufacturing difficulty increase
Solution Approach 1:
The integration of cooling channels and heating elements into a single molded fluid channel component dramatically simplifies assembly. Instead of assembling multiple separate components (cooling plates, heating elements, connectors), the module requires installation of a single pre-integrated fluid channel component, reducing assembly steps and complexity.
Solution Approach 2:
The patent utilizes injection molding technology to manufacture the complex fluid channel structure with integrated cooling passages and heating element positions. By changing the manufacturing parameter from traditional mechanical assembly to plastic injection molding, the complex geometry is achieved in a single manufacturing step, simplifying both production and assembly.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The proposed solution simplifies assembly and manufacturing, reduces component count and costs, and enhances thermal management efficiency for battery packs.
Implementation Method 1
the thermal management module comprises at least one heating element arranged at least partially within the fluid channel, such that the cooling fluid is heatable by the heating element
Implementation Method 2
the thermal management module comprises at least one fluid pump for driving a movement of the cooling fluid through the fluid channel
Implementation Method 3
at least one fluid channel for guiding a cooling fluid through the thermal management module
Data Source
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Figure 4a~4c
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AI summary
A thermal management module (110) for controlling the temperature of a battery pack in a vehicle, is disclosed. The thermal management module (110) comprises - at least one fluid channel (112) for guiding a cooling fluid (122) through the thermal management module (110), wherein the fluid channel (112) consists of two or three plastic components (124), wherein the fluid channel (112) comprises at least one inlet (114) and at least one outlet (116); - at least one fluid pump (118) for driving a movement of the cooling fluid (122) through the fluid channel (112), wherein the fluid pump (118) is fixed to the fluid channel (112); - at least one heating element (120) arranged at least partially within the fluid channel (112), such that the cooling fluid (122) is heatable by the heating element (120). Further, a module manufacturing method of manufacturing a thermal management module (110) is disclosed.