Vehicle Coolant Circuit Deairing with a Shared Expansion Tank
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Solution Overview
Problem
Modern vehicles face challenges with air entering coolant circuits, reducing efficiency and potentially damaging components. The increased number of systems and components due to electrification adds complexity, cost, and space constraints, particularly in managing multiple coolant circuits independently.
Innovation Solution
A vehicle thermal management system featuring a first and second coolant circuit, each with a coolant pump, a coolant duct with an expansion tank, and a connecting conduit with a valve. The valve controls the flow between the circuits, allowing deairing of both circuits using a single expansion tank and enabling independent operation at different temperature levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple independent coolant circuits are used to cool different vehicle systems, then each system can be cooled independently at optimal temperatures, but the complexity, cost, and space requirements increase significantly
Solution Approach 1:
The patent merges multiple coolant circuits into a single integrated thermal management system. The first coolant circuit connects the radiator to both the first and second coolant circuits, allowing all systems to share common coolant flow paths while maintaining independent temperature control through strategically placed control valves. This reduces the number of separate pumps and expansion tanks needed.
Solution Approach 2:
The single coolant circuit is designed to serve multiple functions by cooling different vehicle systems (combustion engine, electric propulsion system, propulsion battery, retarder) simultaneously. The circuit uses control valves to direct coolant flow to different components as needed, making the system universal rather than requiring dedicated circuits for each component.
2Reliability
If each coolant circuit is designed with sufficient capacity for peak power cooling, then each system can be cooled effectively, but the overall system complexity and cost increase
Solution Approach 1:
The patent implements dynamic flow control using control valves that adjust coolant distribution based on real-time thermal demands. Instead of designing each circuit for maximum peak capacity, the system dynamically allocates coolant flow to match actual cooling needs, allowing smaller, more efficient components that can adapt to varying loads.
Solution Approach 2:
The system changes operational parameters (coolant flow rate, temperature) dynamically through control valves to optimize cooling efficiency. By adjusting flow parameters rather than relying on fixed high-capacity circuits, the system achieves reliable cooling with reduced component sizes and lower overall system complexity.
3Ease of manufacture
If air enters the coolant circuit, then the circuit can be filled easily, but air reduces cooling efficiency and may damage coolant pumps
Solution Approach 1:
The patent extracts air from the coolant circuit using expansion tanks positioned at high points in the system. As coolant circulates through the circuit, air bubbles rise to the expansion tanks where they are separated from the coolant. This allows the system to be filled easily while continuously removing air to maintain cooling efficiency and protect pumps from air-induced damage.
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 system effectively deairs both coolant circuits using a single expansion tank, preventing damage to coolant pumps and reducing complexity and cost. It allows for independent operation of coolant circuits and efficient heat management between them, optimizing space utilization and assembly efficiency.
Implementation Method 1
an expansion tank connected to the coolant duct... allows flow of fluid through the first connecting conduit to deair the second coolant circuit via the expansion tank
Implementation Method 2
one or more radiators arranged to transfer heat from the cooling circuit to ambient air
Implementation Method 3
each comprising a coolant pump
Data Source
AI summary
A vehicle thermal management system is disclosed comprising a first and a second coolant circuit each comprising a coolant pump. The first coolant circuit comprises a coolant duct configured to conduct coolant flow through a portion of the first coolant circuit, and an expansion tank connected to the coolant duct. The system further comprises a first connecting conduit connecting the second coolant circuit to the coolant duct, and valve controllable between a first state in which the valve hinders flow of fluid through the first connecting conduit, and a second state in which the valve allows flow of fluid through the first connecting conduit. The present disclosure further relates to a vehicle comprising a vehicle thermal management system.