Integrated Coolant Manifold Layout for Lower EV Thermal Power Use
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Solution Overview
Problem
Current thermal management systems for electric vehicles require significant power to operate due to extensive piping and connections, leading to increased energy consumption and efficiency losses.
Innovation Solution
A thermal management system featuring an integrated coolant controller with a manifold that integrates pumps, valves, and coolant tanks, eliminating unnecessary piping and optimizing fluid flow through multiple circuits, thereby reducing power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple thermal fluid circuits with different valves and hosing are used to carry coolant to various components, then thermal management coverage is improved, but power consumption increases
Solution Approach 1:
The patent integrates multiple thermal fluid circuits into a single unified system with a common coolant tank and pump. The manifold structure combines multiple circuit pathways (engine cooling, radiator, heater core, thermostat) into one integrated assembly, eliminating the need for separate piping systems for each circuit and reducing overall power consumption while maintaining comprehensive thermal management coverage
Solution Approach 2:
The single pump in the integrated coolant controller serves multiple functions by circulating coolant through different circuits based on system needs. The multi-way valve provides universal flow control for multiple destinations (radiator, heater core, engine), replacing the need for multiple dedicated pumps and valves, thereby reducing power consumption while maintaining adaptability
2Adaptability or versatility
If extensive piping and connections are used in thermal management systems, then component connectivity is improved, but device complexity increases
Solution Approach 1:
The manifold integrates multiple piping pathways and connections into a single consolidated component. Instead of having separate hoses and connections for each thermal circuit, the manifold provides integrated flow paths that connect the coolant tank, pump, multi-way valve, and various thermal components, thereby maintaining component connectivity while significantly reducing system complexity
Solution Approach 2:
The manifold acts as an intermediary component that simplifies the connection network. It provides a centralized hub where coolant flow can be distributed to multiple circuits through integrated passages, eliminating the need for complex external piping and multiple connection points, thus reducing device complexity while maintaining full connectivity
3Ease of manufacture
If separate piping systems are used for coolant tank, pump, and valves, then component independence is improved, but manufacturing cost increases
Solution Approach 1:
The integrated coolant controller combines the coolant tank, pump, multi-way valve, and manifold into a single assembled unit. This integration eliminates the need for extensive external piping to connect these components, reducing the quantity of piping material required while maintaining component independence through modular assembly within the integrated housing
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 system reduces power usage by minimizing piping and enhancing fluid flow efficiency, improving the overall thermal management performance and energy efficiency in electric vehicles.
Implementation Method 1
The first pump is configured to pump the flow of the coolant fluid from the coolant tank through the plurality of fluid circuits
Implementation Method 2
The manifold is coupled to each of the coolant tank, the first pump, and the multi-way valve to integrate the components so that each fluid circuit of the plurality of fluid circuits flows through the manifold to eliminate piping between the components and to reduce the amount of power used by the first pump
Implementation Method 3
The temperature sensor docks are each configured to receive a temperature sensor to mount the temperature sensor in fluid communication with one of the plurality of fluid cavities to measure the temperature of the flow of coolant fluid
Data Source
AI summary
A thermal management system is adapted for use in a vehicle to control the heating and/or cooling of the components of the vehicle. The thermal management system includes a plurality of fluid circuits and an integrated coolant controller. The integrated coolant controller is configured to control a flow of coolant fluid through the different fluid circuits.