Dash Module Cooling Structure for EV Front Electronics
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Solution Overview
Problem
In battery electric vehicles, the narrower grille opening leads to insufficient heat dissipation of auxiliary batteries and integrated electronic control units (ECUs) due to reduced airflow, causing potential deterioration of functionality.
Innovation Solution
A vehicle front structure with a dash module that incorporates a channel for cooling refrigerant, allowing heat generating devices like auxiliary batteries and ECUs to be mounted in contact with or close to the dash module, which is cooled by the refrigerant flowing through internal channels or pipes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the grille opening is narrowed in a battery electric vehicle, then the aerodynamic performance is improved, but the heat dissipation of auxiliary batteries and ECUs deteriorates
Solution Approach 1:
The dash module serves as an intermediary heat dissipation component between the auxiliary battery/ECU and the external environment. It provides a dedicated thermal management pathway that is independent of the grille opening, allowing heat to be dissipated through the dash module's cooling channels while maintaining the narrowed grille for aerodynamic efficiency.
Solution Approach 2:
The thermal management system is segmented into separate pathways: the grille opening for general airflow and the dash module's internal cooling channels for targeted heat dissipation. This segmentation allows the grille to be narrowed for aerodynamics while the dash module handles thermal management independently through its own cooling circuit.
2Volume of stationary object
If the auxiliary battery and ECU are disposed near the dash panel, then the space utilization is improved, but the heat dissipation becomes insufficient
Solution Approach 1:
The dash module combines multiple functions into a single component: it serves as the dashboard structure, a mounting surface for the auxiliary battery and ECU, and a heat dissipation device with integrated cooling channels. This merging allows close proximity of heat-generating components while providing immediate thermal management through the dash module's cooling system.
Solution Approach 2:
The dash module acts as an intermediary thermal management device between the heat-generating components (auxiliary battery and ECU) and the cooling refrigerant. By disposing these components near or in contact with the dash module, the refrigerant flowing through the dash module's channels provides efficient heat transfer while maintaining compact spatial arrangement.
3Ease of manufacture
If the dash module is made as a separate body from the frame member, then the manufacturing flexibility is improved, but the structural complexity increases
Solution Approach 1:
The vehicle front structure is segmented into separate modules: the frame member providing structural support and the dash module providing thermal management and dashboard functions. This segmentation allows each component to be manufactured and optimized independently, with the dash module containing integrated cooling channels that would be difficult to incorporate into a monolithic structure.
Solution Approach 2:
The dash module is designed as a multi-functional component that serves as both the dashboard structure and the cooling system housing. By making it a separate body from the frame member, it can be universally applied to different vehicle platforms while providing both structural and thermal management functions, reducing overall system complexity despite the modular approach.
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
Efficient cooling of heat generating devices by direct contact with the dash module, enhancing heat dissipation and maintaining the functionality of auxiliary batteries and ECUs.
Implementation Method 1
the cooling refrigerant flowing through the channel cools the dash module, the at least one heat generating device disposed in contact with or close to the dash module can be cooled
Data Source
AI summary
A vehicle front structure includes a dash module that separates an inside and an outside of a vehicle cabin from each other, the dash module having a channel for a cooling refrigerant extending in the vehicle-width direction, and at least one heat generating device disposed in contact with or close to the dash module.