Integrated Coolant Manifold Layout for EV Thermal Flow Control
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Solution Overview
Problem
Existing thermal management systems in electric vehicles require significant power to operate due to multiple thermal fluid circuits with various valves and hoses, leading to flow restrictions and inefficiencies.
Innovation Solution
An integrated coolant controller with a manifold that integrates the coolant tank, pumps, and multi-way valve, eliminating unnecessary piping and reducing power consumption by directly mounting components onto the manifold, thereby streamlining coolant fluid flow through distinct fluid circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a complex network of hoses and valves is used to distribute coolant fluid through multiple thermal fluid circuits, then the thermal management system can control heating and cooling of various vehicle components, but the power consumption increases and system efficiency decreases
Solution Approach 1:
The patent combines multiple thermal fluid circuits into a single integrated thermal fluid circuit that shares common components (coolant tank, pump, manifold, valves). This merging eliminates redundant piping while maintaining the ability to independently control coolant flow to different components through the shared circuit and valve system, thereby reducing power consumption without sacrificing thermal management versatility.
Solution Approach 2:
The integrated thermal fluid circuit serves multiple functions by distributing coolant to various vehicle components (battery pack, motor, electronics, cabin) through a single circuit architecture. The universal manifold and multi-position valve enable one circuit to perform the work of multiple separate circuits, reducing overall system power requirements while maintaining adaptability across different thermal management needs.
2Adaptability or versatility
If multiple separate thermal fluid circuits with individual valves and hosing are used, then each component can be independently controlled, but the device complexity increases
Solution Approach 1:
The patent merges multiple separate thermal fluid circuits into a single integrated circuit that uses shared components (one coolant tank, one pump, one manifold, and a multi-position valve) to replace multiple individual circuits. This consolidation maintains independent control capability through the valve's ability to direct coolant flow selectively while significantly reducing system structural complexity by eliminating redundant piping and components.
Solution Approach 2:
The integrated circuit employs universal components that perform multiple functions: the manifold distributes coolant to multiple locations, the multi-position valve controls flow direction to different components, and the single pump serves the entire system. This multi-functionality approach enables independent component control without requiring separate dedicated circuits for each component.
3Reliability
If extensive piping and hosing are used to connect the coolant tank, pump, and valves to multiple fluid circuits, then complete coolant distribution is achieved, but the amount of power used by the pump increases
Solution Approach 1:
The patent merges multiple piping systems into a single integrated thermal fluid circuit with shared piping between the coolant tank, pump, manifold, and various vehicle components. This consolidation reduces the total length and complexity of piping required, thereby reducing the hydraulic resistance and power consumption of the pump while maintaining complete coolant distribution capability through the optimized single-circuit architecture.
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 integrated system reduces power usage and eliminates flow restrictions by integrating components, enhancing the efficiency of thermal management in electric vehicles.
Implementation Method 1
The first pump is configured to pump the flow of the coolant fluid from the coolant tank through the plurality of fluid circuits
Implementation Method 2
The manifold is coupled to each of the coolant tank, the first pump, and the multi-way valve to integrate the coolant tank, the first pump, and the multi-way valve so that each fluid circuit of the plurality of fluid circuits flows through the manifold to eliminate piping between the coolant tank, the first pump, and the multi-way valve and to reduce the amount of power used by the first pump to supply the coolant fluid through the different fluid circuits
Data Source
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AI summary
A thermal management system is adapted for use in a vehicle to control the heating and/or cooling of the components of the vehicle. The thermal management system includes a plurality of fluid circuits and an integrated coolant controller. The integrated coolant controller is configured to control a flow of coolant fluid through the different fluid circuits.