Integrated Heat Exchange Module for EV Space and Pressure Loss
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Solution Overview
Problem
Existing vehicle lubrication systems face challenges in optimizing space utilization within limited and fixed spaces while maintaining structural integrity and efficient lubrication functionality.
Innovation Solution
A heat exchange system comprising a Heat Exchange Module (HEM) positioned between the inverter and gearbox, serving as both an enclosure for the HEM assembly and a structural support member, with a six-port design that combines coolant and oil flow to enhance space efficiency and reduce pressure drops.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a heat exchange module is positioned between the inverter and gearbox to serve as both an enclosure and structural support member, then space utilization is optimized and manufacturing costs are reduced, but the device complexity increases due to the multi-functional integration
Solution Approach 1:
The patent combines the heat exchange module with the structural support member and enclosure functions into a single integrated component. The HEM assembly serves multiple purposes: it provides heat exchange functionality, acts as a structural support between the inverter and gearbox, and serves as an enclosure for the heat exchange components. This merging of functions reduces the number of separate parts needed and optimizes space utilization within the vehicle's limited interior space.
Solution Approach 2:
The heat exchange module is designed to perform multiple functions simultaneously. It not only exchanges heat between fluids but also provides structural support to maintain the spatial relationship between the inverter and gearbox, and acts as an enclosure protecting the internal heat exchange components. This multi-functionality reduces the overall component count and simplifies the system architecture.
2Loss of energy
If a six-port design is used to combine coolant and oil flow, then pressure drops are reduced and lubrication efficiency is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The heat exchange module incorporates a six-port design that segments the fluid flow into separate pathways for coolant and oil. This segmentation allows for optimized flow paths that reduce pressure drops and improve lubrication efficiency. The multiple ports enable independent control and optimization of each fluid's flow characteristics, minimizing energy loss while maintaining manageable manufacturing tolerances.
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 solution provides a compact, cost-effective, and efficient heat exchange system that optimizes space utilization, reduces manufacturing and maintenance costs, and improves vehicle dynamics by minimizing pressure drops and enhancing lubrication system performance.
Implementation Method 1
heat exchange system comprising a heat exchange module (HEM)
Data Source
AI summary
Disclosed are embodiments generally directed to a heat exchange system comprising a heat exchange module (HEM) that is strategically positioned within the vehicle and supports a combined lubrication system providing lubrication functionality for the vehicle. The HEM is positioned between an inverter and a gear box within the example electric vehicle. The HEM includes a plurality of ports and corresponding passages for coolant flow and oil flow.