Integrated Coolant Manifold for EV Battery Thermal Routing
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Solution Overview
Problem
Conventional thermal management systems in electrified vehicles are complex, inefficient, and costly due to numerous coolant lines and valves, which affect energy efficiency, packaging, and manufacturing costs, and struggle to maintain optimal battery pack temperature across varying ambient conditions.
Innovation Solution
A coolant distribution module with a single module body incorporating two multi-port manifold valves that provide multiple operating states through various flow distribution paths, reducing the number of coolant lines and connectors, and utilizing a compact design with a single T-fitting, enabling efficient thermal management across different vehicle platforms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional thermal management systems use multiple coolant lines and valves, then they can manage heat from battery cells, but the system complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple coolant distribution functions into a single integrated manifold assembly that serves the battery pack. This single manifold replaces what would traditionally require multiple separate valves and coolant lines, thereby reducing system complexity while maintaining the ability to manage heat from battery cells effectively.
Solution Approach 2:
The manifold assembly is designed to perform multiple functions: it distributes coolant to different battery modules, collects coolant from various heat exchangers, and provides thermal management for multiple battery cells simultaneously. This multi-functional design reduces the overall number of components needed in the thermal management system.
2Ease of operation
If conventional thermal management systems use numerous valves and connectors, then they can control coolant flow, but the number of hoses and connectors increases manufacturing cost
Solution Approach 1:
The patent integrates multiple valve functions and connector points into a single manifold body, reducing the total number of separate hoses and connectors required. This integration maintains full coolant flow control capability while significantly reducing the bill of materials and assembly complexity.
Solution Approach 2:
The manifold is designed with multiple independent ports and internal passages that can be controlled independently, allowing segmented control of coolant flow to different battery modules. This segmentation provides operational flexibility without requiring multiple external valves.
3Adaptability or versatility
If conventional systems use multiple separate valves, then they can provide flow distribution paths, but the packaging space and vehicle integration difficulty increase
Solution Approach 1:
The patent consolidates multiple valve functions and flow distribution capabilities into a single compact manifold assembly that integrates directly with the battery pack structure. This integration eliminates the need for separate valve housings and associated mounting space, reducing overall packaging requirements.
Solution Approach 2:
The manifold assembly is designed to nest within or integrate with the existing battery pack structure, utilizing available space efficiently. The compact design allows the thermal management components to be nested within the battery module architecture rather than requiring separate mounting locations.
4Reliability
If conventional thermal management systems use many coolant lines, then they can manage heat efficiently, but the energy efficiency and vehicle range decrease
Solution Approach 1:
The patent reduces the total length and number of coolant lines required by integrating flow distribution into a single manifold assembly. This reduction in coolant line length decreases the thermal resistance and pumping power required, thereby improving overall system efficiency and extending vehicle range.
Solution Approach 2:
The manifold design optimizes coolant flow parameters including velocity, pressure distribution, and temperature uniformity across battery modules. By improving flow distribution efficiency, the system achieves better heat management with lower pumping power requirements, preserving more energy for vehicle propulsion.
Data Source
AI summary
This disclosure details a coolant distribution module as used in a thermal management systems for thermally managing electrified vehicle components. An exemplary coolant distribution module includes a module body including a plurality of inlet ports and a plurality of outlet ports, a first manifold valve encompassed within the module body, and a second manifold valve encompassed within the module body. The first manifold valve includes a plurality of first valve inputs wherein each first valve input is in communication with at least one inlet port of the plurality of inlet ports, and a plurality of first valve outputs wherein each first valve output is in communication with at least one outlet port of the plurality of outlet ports. The second manifold valve includes a plurality of second valve inputs wherein each second valve input is in communication with at least one inlet port of the plurality of inlet ports, and a plurality of second valve outputs wherein each second valve output is in communication with at least one outlet port of the plurality of outlet ports.