Integrated EV Thermal Manager for Compact Multi-Loop Assembly
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Solution Overview
Problem
The assembly of thermal management systems in electric vehicles is difficult due to the independent circulation lines requiring separate assembly of devices such as valves and pumps, leading to inefficiencies and increased space usage.
Innovation Solution
A thermal manager with integrated heat transfer tube sets and a valve assembly that allows for mode switching to connect and disconnect different devices, reducing the need for separate line and valve installations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If independent circulation lines with separate devices are used, then each device can be independently controlled, but the assembly complexity and space requirements increase
Solution Approach 1:
The patent combines multiple independent circulation lines into a single integrated thermal management system. The housing accommodates multiple heat transfer tube sets that form different circulation paths (first circulation path for battery pack, second circulation path for drive unit), while sharing common components like the pump and control unit. This merging reduces assembly complexity while maintaining independent control through the control unit's ability to regulate different paths separately.
Solution Approach 2:
The thermal management system is designed with multi-functionality where a single system handles thermal management for both the battery pack and drive unit. The pump can circulate heat transfer fluid through different paths, and the control unit can switch between cooling and heating modes, serving multiple functions with a unified structure rather than requiring separate independent systems.
2Adaptability or versatility
If independent circulation lines with separate devices are used, then each device can be independently controlled, but the space occupied by the thermal management system increases
Solution Approach 1:
The patent merges multiple circulation lines into a compact integrated structure housed within a single housing. The heat transfer tube sets are arranged to accommodate multiple circulation paths (battery pack path and drive unit path) in close proximity, sharing common components like the pump and control unit, thereby reducing the overall space footprint compared to separate independent systems.
Solution Approach 2:
The thermal management system employs a nested arrangement where heat transfer tube sets are positioned within the housing in a space-efficient manner. The tubes are routed to accommodate different circulation paths while nesting components within the compact housing structure, maximizing space utilization and minimizing the external dimensions of the thermal management system.
3Ease of manufacture
If separate assembly of circulation lines and devices is performed, then each component can be manufactured independently, but the assembly time and labor requirements increase
Solution Approach 1:
The patent combines multiple circulation lines and devices into a pre-integrated assembly that can be manufactured as a unified module. The housing, heat transfer tube sets, pump, and control unit are designed to work together as a single thermal management system, reducing the number of separate assembly operations required while maintaining the ability to manufacture components using standardized processes.
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
This integration improves assembly efficiency and reduces space requirements for thermal management systems in electric vehicles by allowing for streamlined connection and disconnection of heat transfer loops.
Implementation Method 1
Water, antifreeze and other heat transfer media circulate in the battery circulation line and the power circulation line
Implementation Method 2
the valve assembly is used to selectively communicate with a different valve port when the thermal manager performs mode switching, so as to realize connection and disconnection of a heat transfer loop
Data Source
AI summary
The present application provides an electric vehicle and a thermal manager thereof. The thermal manager includes a housing, and a plurality of heat transfer tube sets are accommodated in the housing, and each heat transfer tube set is used for connecting a device; a valve assembly is arranged on a front surface of the housing, and the valve assembly is provided with a plurality of valve ports; each valve port is opposite to and communicates with a second end of at least one heat transfer branch tube in a front-and-rear direction, and the two heat transfer branch tubes in a same set are each in communication with a different valve port; the valve assembly is used to selectively communicate with a different valve port when the thermal manager performs mode switching. The electric vehicle includes a motor, a battery, a radiator and the thermal manager as above.