Cargo Bed Thermal Management Flow Control Assembly
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Solution Overview
Problem
Electrified vehicles face challenges in managing thermal energy levels of their traction batteries, which can affect efficiency and lifespan, as existing systems lack effective control over air flow to heat exchange modules.
Innovation Solution
A thermal management assembly that includes a heat exchange module between inner and outer panels of a cargo bed, with a flow control structure such as louvers or flaps to regulate air flow, allowing for selective adjustment of air flow to manage thermal energy levels, and a fan to facilitate air movement through the module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a heat exchange module is installed in the cargo bed to manage thermal energy levels, then thermal management capability is improved, but device complexity increases
Solution Approach 1:
The heat exchange module is integrated into the cargo bed structure itself, combining the thermal management function with the existing cargo bed. This merging approach adds thermal management capability without requiring a completely separate system, thereby improving reliability while limiting the increase in device complexity.
Solution Approach 2:
The cargo bed is designed to serve multiple functions: it acts as both a storage structure and a thermal management system housing. The heat exchange module utilizes the cargo bed's existing structure and airflow paths, allowing the same space to fulfill both cargo storage and battery thermal regulation functions.
2Adaptability or versatility
If a flow control structure is added to selectively restrict or permit air flow, then adaptability is improved, but device complexity increases
Solution Approach 1:
The flow control structure incorporates moveable components such as adjustable flaps or louvers that can dynamically change the airflow passage cross-sectional area. These components can be positioned at different angles or openings to selectively restrict or permit air flow, enabling the system to adapt to varying thermal management requirements based on operational conditions.
3Adaptability or versatility
If the inlet duct is made moveable between extended and retracted positions, then adaptability is improved, but device complexity increases
Solution Approach 1:
The inlet duct is designed as a moveable component that can be positioned in different states: extended to project from the cargo bed side for maximum airflow intake, or retracted to be substantially flush with the cargo bed surface for minimal protrusion. This dynamic positioning capability allows the system to adapt airflow intake based on vehicle speed, thermal demands, or aerodynamic requirements.
Solution Approach 2:
The inlet duct is divided into separable sections, allowing it to be independently positioned relative to the cargo bed. This segmentation enables the duct to be extended or retracted without affecting the structural integrity of the cargo bed, facilitating flexible airflow control while maintaining a relatively simple overall design.
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
This solution effectively manages thermal energy levels of traction batteries by controlling air flow, enhancing battery efficiency and lifespan, and providing flexible cooling based on operational needs.
Implementation Method 1
exchanging thermal energy between the air and another fluid at a heat exchange module
Implementation Method 2
a fan to facilitate air movement through the module
Data Source
AI summary
An exemplary vehicle assembly includes, among other things, an inlet duct that opens to a duct opening within a side of a cargo bed. The inlet duct is configured to communicate a flow of air to a heat exchange module that manages thermal energy levels of a traction battery. A flow control structure is moved relative to the duct opening to selectively restrict or permit the flow of air entering the inlet duct through the duct opening. A flow control method includes, among other things, selectively blocking at least a portion of a duct opening to adjust a flow of air moved through the duct opening into an inlet duct. To manage thermal energy within a traction battery, the method further includes exchanging thermal energy between the air and another fluid at a heat exchange module that is disposed within a chamber of a cargo bed.