Integrated Cooling Manifold Layout for Compact EV Thermal Modules
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Solution Overview
Problem
The existing cooling systems for electric and hybrid vehicles are bulky and heavy due to the need for separate cooling modules and complex pipe layouts, which complicates spatial efficiency and weight reduction.
Innovation Solution
An integrated cooling module with a manifold that stores coolant and features internal refrigerant channels, allowing components like condensers, chillers, and water pumps to be mounted directly on the manifold, eliminating the need for hoses or pipes and maximizing spatial efficiency by elongating the manifold in the gravitational direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate cooling modules and complex pipe layouts are used for battery cooling system, heat pump system, and cooling means, then the cooling function is achieved, but the size and weight of the cooling system are increased
Solution Approach 1:
The patent combines the battery cooling system, heat pump system, and cooling means into a single integrated cooling module. The manifold integrates coolant storage, refrigerant channels, and mounting structures for multiple components (compressor, condenser, expansion valve, evaporator, water pump) into one unified structure, eliminating the need for separate cooling modules and reducing overall system weight while maintaining all required cooling functions.
2Reliability
If separate cooling modules and complex pipe layouts are used for battery cooling system, heat pump system, and cooling means, then the cooling function is achieved, but the size of the cooling system is increased
Solution Approach 1:
The patent combines the battery cooling system, heat pump system, and cooling means into a single integrated cooling module. The manifold integrates coolant storage, refrigerant channels, and mounting structures for multiple components (compressor, condenser, expansion valve, evaporator, water pump) into one unified structure, eliminating the need for separate cooling modules and reducing overall system size while maintaining all required cooling functions.
Solution Approach 2:
The manifold is designed with nested structures where the refrigerant channel is formed inside the housing that constitutes the manifold, and the coolant storage part is positioned in the hollowed interior of the second manifold. This nesting arrangement maximizes spatial efficiency and minimizes the overall size of the cooling system.
3Reliability
If separate cooling modules are used for battery cooling system, heat pump system, and cooling means, then the cooling function is achieved, but the complexity of connection pipes is increased
Solution Approach 1:
The patent combines the battery cooling system, heat pump system, and cooling means into a single integrated cooling module. The manifold integrates coolant storage, refrigerant channels, and mounting structures for multiple components (compressor, condenser, expansion valve, evaporator, water pump) into one unified structure, eliminating the need for separate cooling modules and reducing overall system weight while maintaining all required cooling functions.
4Reliability
If components are mounted separately with hoses or pipes, then the cooling function is achieved, but the spatial efficiency is reduced
Solution Approach 1:
The patent combines the battery cooling system, heat pump system, and cooling means into a single integrated cooling module. The manifold integrates coolant storage, refrigerant channels, and mounting structures for multiple components (compressor, condenser, expansion valve, evaporator, water pump) into one unified structure, eliminating the need for separate cooling modules and reducing overall system weight while maintaining all required cooling functions.
Solution Approach 2:
The manifold is designed with nested structures where the refrigerant channel is formed inside the housing that constitutes the manifold, and the coolant storage part is positioned in the hollowed interior of the second manifold. This nesting arrangement maximizes spatial efficiency and minimizes the overall size of the cooling system.
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
This design miniaturizes and lightens the cooling system, reduces assembly complexity, and enhances spatial efficiency by integrating components within the manifold, effectively managing coolant and refrigerant flow.
Implementation Method 1
a coolant storage part in which a coolant is stored and flows
Implementation Method 2
refrigerant channels, through which a refrigerant flows, are provided around the coolant storage part
Data Source
AI summary
The present invention relates to an integrated cooling module applied to a vehicle cooling system, and more particularly, to an integrated cooling module in which components are integrated with a manifold to eliminate a hose or pipe and reduce a size and weight of the entire cooling system, and the manifold is elongated in a gravitational direction to advantageously store a coolant therein and intensively mount the components, and an internal heat exchanger is provided in the manifold to maximize spatial efficiency.