Plate-Shaped Cooling Manifold Layout for Lighter Vehicle 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 circuits and complex pipe layouts for refrigerant and coolant supply, which complicates the layout and increases the size and weight of the cooling module.
Innovation Solution
An integrated cooling module with a plate-shaped manifold that integrates components such as a condenser, chiller, PT sensor, and expansion valve, where the manifold is formed by coupling an arcuate plate and a flat plate to create refrigerant channels, eliminating the need for hoses or pipes and improving manufacturability, rigidity, and sealability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate cooling circuits and complex pipe layouts are used for refrigerant and coolant supply, then the cooling system can effectively cool the motor, fuel cell, and battery, but the size and weight of the cooling module are increased
Solution Approach 1:
The patent integrates the refrigerant manifold and coolant manifold into a single plate-shaped manifold structure. The first manifold body contains both refrigerant channels and coolant channels, allowing the cooling system to cool the motor, fuel cell, and battery effectively while eliminating the need for separate cooling circuits and complex pipe layouts, thereby reducing the overall size and weight of the cooling module
Solution Approach 2:
The plate-shaped manifold serves multiple functions simultaneously: it acts as both a refrigerant distribution system and a coolant distribution system. The manifold body includes both refrigerant channels for the air conditioning system and coolant channels for the battery cooling system, making the single component universal and eliminating the need for separate dedicated cooling circuits
2Reliability
If separate cooling circuits and complex pipe layouts are used, then the cooling system can effectively cool the motor, fuel cell, and battery, but the layout of connection pipes in the engine room becomes complicated
Solution Approach 1:
The patent merges the refrigerant manifold and coolant manifold into a single integrated plate-shaped manifold. This integration simplifies the layout in the engine room by consolidating multiple connection points and channels into one compact structure, eliminating the need for complex pipe routing while maintaining effective cooling of all components
3Ease of manufacture
If a traditional manifold structure is used, then the manufacturing process is simple, but the rigidity and sealability are insufficient
Solution Approach 1:
The patent employs a curved surface on the first plate of the plate-shaped manifold. This curved surface configuration enhances the rigidity and structural strength of the manifold while maintaining manufacturability through standard forming processes, resolving the contradiction between simple manufacturing and sufficient rigidity
4Ease of manufacture
If a traditional manifold structure is used, then the manufacturing process is simple, but the sealability is insufficient
Solution Approach 1:
The curved surface configuration of the first plate in the plate-shaped manifold improves sealability by providing better contact surfaces for sealing elements. The curvature allows for more effective sealing against the second plate while maintaining manufacturability through standard forming processes
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 plate-shaped manifold to eliminate a hose or pipe and reduce a size and weight of the entire cooling system, and the plate-shaped manifold is configured by coupling an arcuate plate and a flat plate to improve manufacturability, rigidity, and sealability.