Integrated Coolant Control Module for Low-Resistance EV Cooling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Eco-friendly vehicle cooling systems face challenges in space constraints, complex hose routing, and high coolant flow resistance, leading to increased man-hours and pump load during component installation and operation.
Innovation Solution
A modular coolant control module that integrates various cooling system components, including a housing with coolant inlets and outlets, pumps, control valves, and a controller, to reduce part count, assembly time, and flow resistance, while enhancing scalability and installation convenience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If various cooling system components are individually arranged and connected in an eco-friendly vehicle, then each component can be independently controlled and maintained, but the layout space requirement increases, assembly time increases, and hose routing becomes complex
Solution Approach 1:
The patent combines multiple cooling system components (coolant pump, control valve, radiator, battery thermal management components) into a single integrated coolant control module. This merging reduces the number of separate parts that need to be arranged and connected, simplifying the overall system layout while maintaining the functional capabilities of each individual component through modular design elements.
Solution Approach 2:
The integrated coolant control module is designed to perform multiple functions simultaneously - cooling the engine, cooling the battery, and managing thermal conditions for various power electronics. The module uses a single coolant circulation system with strategically placed outlets and passages to serve multiple thermal management needs, reducing the requirement for separate cooling circuits.
2Adaptability or versatility
If multiple separate components are used for cooling system, then functional flexibility is improved, but the number of parts increases and assembly time increases
Solution Approach 1:
Multiple cooling system components are merged into a single integrated module that can be installed as one unit in the vehicle. The module includes internally connected coolant passages, mounted pumps, and integrated control valves, eliminating the need for separate installation and connection of multiple individual components while maintaining functional flexibility through internal routing options.
Solution Approach 2:
The cooling system components are pre-assembled and pre-configured into a complete module before vehicle assembly. Coolant passages are pre-routed, connections are pre-established, and the entire assembly is tested as a unit, significantly reducing on-vehicle assembly time and installation complexity.
3Ease of operation
If complex hose routing is used to connect cooling components, then all components can be connected, but flow resistance increases and pump load increases
Solution Approach 1:
By integrating multiple components into a single module with internally connected passages, the patent eliminates long external hose routes. The coolant flows through short, direct passages between components within the module, significantly reducing flow resistance and the energy required by the pump to maintain circulation.
Solution Approach 2:
The patent extracts the coolant circulation function from complex external hose routing and relocates it to internal passages within the integrated module. This extraction of the flow path from the external environment to the internal structure of the module simplifies the routing and reduces flow resistance.
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 integrated design reduces the size and weight of the cooling system, decreases assembly time, improves performance and durability, and lowers the load on coolant pumps by minimizing hose length and flow resistance.
Implementation Method 1
a plurality of coolant pumps coupled to the pump mounting part of the housing
Implementation Method 2
a control valve provided inside the housing to switch a direction of the coolant
Data Source
AI summary
An embodiment coolant control module includes a housing including a coolant inlet configured to receive a coolant, a coolant outlet configured to discharge the coolant, an internal passage connecting the coolant inlet and the coolant outlet, and a pump mounting part adjacent to the coolant outlet. The coolant control module further includes a control valve disposed inside the housing and configured to change a direction of the coolant, a coolant pump coupled to the pump mounting part of the housing, a driving motor unit mounted on the housing, connected to the control valve, and configured to drive the control valve, and a controller mounted on the housing, connected to the coolant pump and the driving motor unit, and configured to control an operation of the coolant pump and the driving motor unit.