Centralized Cooling Manifold for Multi-Zone Vehicle Temperature Control
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Solution Overview
Problem
Modern vehicle cooling systems for electrified and hybrid drivetrains are complex and costly due to their highly distributed architectures, with coolant temperature regulation being inaccurate and difficult to maintain.
Innovation Solution
A centralized fluid distribution manifold with integrated valves, sensors, and a controller to regulate coolant flow and temperature in a centralized manner, reducing complexity and improving temperature control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a highly distributed cooling system architecture is used, then the cooling system can serve multiple zones (battery, cabin, charging electronics, motor), but the system complexity and cost increase significantly
Solution Approach 1:
The patent consolidates multiple distributed cooling control functions into a single centralized fluid distribution manifold. This manifold integrates multiple valves, temperature sensors, and flow control mechanisms into one unified component that serves all cooling zones (battery, cabin, charging electronics, motor), thereby reducing the number of separate components and simplifying system architecture while maintaining multi-zone cooling capability
Solution Approach 2:
The centralized manifold performs multiple functions simultaneously: it distributes coolant to different zones, regulates flow to each zone independently via integrated valves, monitors temperature across zones through mounted sensors, and controls cooling distribution based on system demands. This multi-functional integration reduces overall system complexity while preserving adaptability to various cooling requirements
2Ease of operation
If distributed coolant distributor valves and sensors are separated throughout the vehicle, then each zone can be controlled independently, but the installation and maintenance cost increases
Solution Approach 1:
The patent combines multiple previously separate components (valves, sensors, manifolds) into a single integrated fluid distribution manifold. This consolidation reduces the number of individual parts that need to be installed and maintained, lowering installation costs and simplifying maintenance procedures while preserving independent zone control capability through integrated valves for each cooling zone
Solution Approach 2:
The integrated manifold serves as a universal control hub that provides independent zone control functionality while reducing overall system complexity. By housing multiple valves and sensors in one unit, it maintains the ability to independently regulate each cooling zone while reducing the number of separate installation points and maintenance interventions required
3Adaptability or versatility
If multiple separate cooling loops and sub-loops are implemented, then comprehensive cooling coverage is achieved, but the system becomes expensive to implement and maintain
Solution Approach 1:
The patent merges multiple separate cooling loops into a unified system managed by a single centralized manifold. This manifold provides comprehensive cooling coverage for all zones (battery, cabin, charging electronics, motor) through integrated flow control, reducing the number of separate loops and components required while maintaining comprehensive cooling capability
Solution Approach 2:
The centralized manifold provides universal cooling distribution across all system zones through integrated multi-zone control. It handles multiple cooling demands simultaneously with a single system architecture, reducing implementation complexity and cost while maintaining comprehensive cooling coverage for all vehicle components
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 centralized manifold provides efficient, cost-effective temperature regulation by integrating sensors and valves, enhancing coolant management and reducing installation and maintenance costs.
Implementation Method 1
multiple valves arranged fluidly between the secondary inlet and the secondary outlet to regulate fluid flow through its respective secondary passageway
Implementation Method 2
at least one temperature sensor or pressure sensor in fluid communication with the primary passageway
Implementation Method 3
at least one temperature sensor or pressure sensor in fluid communication with the primary passageway
Implementation Method 4
a pump that is mounted to the housing and in fluid communication with the primary passageway and configured to circulate a coolant through at least one of the main cooling loop and the zone cooling loop
Implementation Method 5
the system includes at least one heat exchanger fluidly arranged in the main cooling loop
Data Source
AI summary
A fluid distribution manifold for a vehicle cooling system includes a housing that includes a primary passageway that extends between a primary inlet and a primary outlet configured to be in fluid communication with a main cooling loop, the housing has multiple secondary passageways each fluidly connected to the primary passageway at a secondary inlet, the multiple secondary passageways each have a secondary outlet that is configured to be in fluid communication with a zone cooling loop, multiple valves that are supported by the housing, each of the secondary passageways have one of the multiple valves arranged fluidly between the secondary inlet and the secondary outlet to regulate fluid flow through its respective secondary passageway, and a least one temperature sensor or pressure sensor in fluid communication with the primary passageway.