Coolant Tank Coupling Layout for Serviceable Multi-Circuit Routing
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Solution Overview
Problem
Electric vehicles require complex cooling systems with separate coolant circuits for engine heat dissipation, battery heating/cooling, and interior temperature control, leading to space inefficiency, accessibility issues, and increased manufacturing complexity.
Innovation Solution
A coolant routing system with a coolant tank and manifold assembly featuring a coupling device formed by the tank's wall, allowing external access and easy servicing, and incorporating rigid coolant channels and external control valves for multiple circuits, reducing internal components and thermal bridges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If device components are moved inside the coolant tank to implement multiple coolant circuits, then space efficiency is improved, but accessibility for maintenance and manufacturing complexity worsen
Solution Approach 1:
The system is divided into modular components: the coolant tank, the coupling device with control valves, and the coolant manifold assembly. This segmentation allows the coupling device and manifold to be independently accessed and serviced without draining the entire tank, resolving the accessibility issue while maintaining space-efficient integration.
Solution Approach 2:
The coupling device acts as an intermediary component positioned at the interface between the coolant tank and the coolant manifold assembly. It provides external access points for control valves and connection points, enabling maintenance without internal tank intervention while still achieving compact integration.
2Volume of moving object
If device components are moved inside the coolant tank, then space efficiency is improved, but thermal bridge control complexity increases
Solution Approach 1:
The control valves are extracted from the internal tank environment and positioned in the coupling device at the tank's exterior interface. This extraction eliminates thermal bridges that would exist if valves were mounted internally on tank walls, reducing thermal control complexity while maintaining compact space utilization.
3Quantity of substance
If the coolant tank is enlarged to provide sufficient coolant capacity, then coolant storage capacity is improved, but manufacturing complexity and space efficiency worsen
Solution Approach 1:
The coupling device is merged with the coolant tank structure, forming an integrated assembly where the coupling device utilizes the tank wall as part of its structure. This merging allows sufficient coolant capacity in a compact tank while integrating control functions without requiring a larger, more complex tank design.
4Measurement precision
If multiple coolant circuits are implemented with separate control, then circuit control precision is improved, but device complexity increases
Solution Approach 1:
The coupling device serves multiple functions: it provides structural support as part of the tank wall, houses control valves for multiple coolant circuits, and offers external access points for maintenance. This multi-functionality enables precise control of multiple circuits without proportionally increasing overall system complexity.
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 provides space-efficient, easily maintainable, and precise control of multiple coolant circuits with reduced thermal interference and manufacturing complexity, maximizing coolant capacity and simplifying assembly.
Implementation Method 1
at least one coolant pump, which is configured to pump the coolant into at least one coolant circuit
Implementation Method 2
coolant can be exchanged between an interior of the coupling device and the at least one coolant pump and between the interior of the coupling device and the coolant manifold assembly
Data Source
AI summary
A coolant routing system for a vehicle having a plurality of coolant circuits, for instance an electric drive vehicle. A coolant tank stores a coolant, and a coolant manifold assembly has a plurality of coolant tubes that are each configured to form a part of one of the coolant circuits. At least one coolant pump is configured to pump the coolant into at least one coolant circuit. A coupling device is configured to introduce the coolant from the coolant tank into the coolant circuits. The coupling device is formed at least in part by a wall of the coolant tank and is coupled to both the at least one coolant pump and the coolant manifold assembly so that coolant can be exchanged between an interior of the coupling device and the at least one coolant pump and between the interior of the coupling device and the coolant manifold assembly.