Integrated Cooling Plate Layout for Compact EV Thermal Modules

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Solution Overview

Problem

Conventional electric vehicle thermal management systems require numerous thermal management components that are dispersed, leading to increased space, weight, and cost due to the use of multiple cooling hoses and tubes, which complicates assembly and increases flow resistance and heat leakage.

Innovation Solution

A multi-channel cooling pipeline integration apparatus in a rectangular plate shape with integrated cooling pipelines, component mounting points, and connection ports, allowing for compact arrangement and integration of thermal management components without the need for numerous hoses or tubes, optimizing pipeline layout and reducing weight and cost.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If multiple thermal management components are dispersedly arranged and connected with numerous cooling hoses or nylon tubes, then each component can be independently installed and maintained, but the system occupies large arrangement space, increases weight, and raises costs

Engineering Contradiction:

ImproveIndependent component installationVSAvoidSystem weight

Core Design Contradiction:

Ease of manufactureVSWeight of stationary object

Solution Approach 1:

The patent merges multiple thermal management components (expansion tank, water pump, heat exchanger, condenser, etc.) into a single integrated assembly where these components are directly connected through internal passages formed in one piece, eliminating the need for numerous separate cooling hoses and nylon tubes, thereby reducing system weight and arrangement space

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated assembly serves multiple functions simultaneously: it acts as a structural support framework, a fluid distribution network with multiple cooling channels, and a mounting platform for various thermal management components, replacing what would traditionally require separate structural elements, hoses, and connectors

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of manufacture

Engineering Contradiction:

ImproveIndependent component installationVSAvoidArrangement space

Core Design Contradiction:

Ease of manufactureVSArea of stationary object

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated assembly employs a nested arrangement where smaller components are positioned within or adjacent to larger components, and multiple cooling channels are nested within the structural framework, maximizing space utilization and minimizing the overall footprint of the thermal management system

Inventive Principle:

Principle #7Nested doll (Nesting)

3Ease of manufacture

If multiple cooling hoses or nylon tubes are used to connect thermal management components, then component flexibility and independent replacement are improved, but system costs increase

Engineering Contradiction:

ImproveComponent flexibilityVSAvoidNumber of cooling hoses and tubes

Core Design Contradiction:

Ease of manufactureVSQuantity of substance

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention extracts and eliminates the unnecessary intermediate connection elements (cooling hoses and nylon tubes) from the system by directly integrating the fluid passages into the main assembly structure, keeping only the essential components while removing redundant parts that increase cost and complexity

Inventive Principle:

Principle #2Taking out (Extraction)

4Ease of manufacture

If multiple cooling hoses or nylon tubes are used to connect thermal management components, then component flexibility and independent replacement are improved, but system weight increases

Engineering Contradiction:

ImproveComponent flexibilityVSAvoidSystem weight

Core Design Contradiction:

Ease of manufactureVSWeight of stationary object

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Inventive Principle:

Principle #2Taking out (Extraction)

5Ease of manufacture

If numerous cooling hoses or nylon tubes are used for connections, then component assembly flexibility is improved, but manufacturing complexity and difficulty increase

Engineering Contradiction:

ImproveAssembly flexibilityVSAvoidPipeline layout complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS12558940B2Multi-channel cooling pipeline integration apparatus, thermal management integration module and electric vehicle

Publication Date: 2026.02.24 ZHEJIANG GEELY HLDG GRP CO LTD

AI summary

A multi-channel cooling pipeline integration apparatus, a thermal management integration module, and an electric vehicle are provided, which belong to the field of vehicle technologies. The multi-channel cooling pipeline integration apparatus is in a substantially rectangular plate shape, and has a plurality of cooling connection pipelines formed therein. A plurality of component mounting points and a plurality of component connection ports are disposed on a surface of the multi-channel cooling pipeline integration apparatus. The plurality of component mounting points is configured to have at least two thermal management components mounted thereon. Each of the plurality of component connection ports is in communication with a corresponding one of the plurality of cooling connection pipelines, to enable the at least two thermal management components to be connected to the plurality of cooling connection pipelines. The at least two thermal management components are configured to be connected to each other.