Central Manifold Cooling Module to Reduce Hose Layout Complexity
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Solution Overview
Problem
The existing cooling systems in electric and hybrid vehicles are bulky and heavy due to separate components and complex pipe layouts, which complicate the refrigerant and coolant supply to heat pump and battery cooling systems.
Innovation Solution
An integrated cooling module with a central manifold that integrates refrigerant flow channels and components, eliminating hoses and pipes, and featuring distinct pressure and temperature zones in the channels to optimize refrigerant flow and reduce system size and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate components and pipe layouts are used for battery cooling system, heat pump system, and cooling system, then each system can function independently, but the size and weight of the cooling module are increased and the layout becomes complicated
Solution Approach 1:
The patent combines the battery cooling system, heat pump system, and cooling system into a single integrated cooling module. The manifold integrates multiple refrigerant flow channels that serve different functions (battery cooling, heat pump, general cooling) within one unified structure, eliminating the need for separate components and reducing layout complexity while maintaining independent system functions through dedicated flow channels
Solution Approach 2:
The manifold is designed as a multi-functional component that handles multiple refrigerant flow channels simultaneously. It serves as a distribution hub for battery cooling, heat pump operation, and general cooling needs, allowing one component to perform multiple functions that previously required separate systems
2Reliability
If separate components and pipes are used for each cooling system, then system functions can be maintained, but the weight of the cooling module is increased
Solution Approach 1:
By merging separate cooling systems into a single integrated manifold structure, the patent eliminates redundant components and piping. The unified design reduces the total weight of the cooling module while maintaining all necessary cooling functions through efficiently arranged internal flow channels
Solution Approach 2:
The patent extracts and eliminates unnecessary hoses and pipes from the system by integrating their functions directly into the manifold structure. This removal of excess components directly reduces the overall weight while preserving essential cooling capabilities
3Reliability
If separate components and pipes are used for each cooling system, then system operations can be maintained, but hoses or pipes are excluded and miniaturization is achieved
Solution Approach 1:
The patent merges multiple cooling operations into a single compact manifold structure. By combining battery cooling channels, heat pump channels, and general cooling channels within one integrated component, the system achieves miniaturization while maintaining all necessary cooling operations through efficient spatial arrangement of flow channels
Solution Approach 2:
The manifold utilizes three-dimensional spatial arrangement of refrigerant flow channels to accommodate multiple cooling functions in a compact volume. By organizing channels in different dimensions and levels within the manifold structure, the patent reduces the overall system size while maintaining functional independence of each cooling pathway
Data Source
AI summary
The present invention relates to an integrated cooling module including a central manifold having a mounting space in which components may be mounted, refrigerant flow channels in which a refrigerant may flow, and communication holes for allowing the components and the refrigerant flow channels to communicate with one another, such that the components are integrated around the central manifold, thereof excluding hoses or pipes and achieving miniaturization and weight reduction of an entire cooling system.