Integrated Heat Management Assembly for Low-Connection Battery Cooling
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Solution Overview
Problem
The existing battery heat management systems in electric and hybrid vehicles are complex and prone to weight and structural issues due to separate components connected by pipes, which can lead to vibration resistance problems and mechanical/electrical complexities.
Innovation Solution
A heat management assembly integrating a heat exchange core body and a valve component through welding, with a sensor connected to a circuit board, reducing the need for multiple connections and simplifying the structure by fixing the valve component above the heat exchange core body, allowing for temperature and pressure detection within a dedicated flow channel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the heat exchanger and expansion valve are connected by pipes, then the system is easier to manufacture and assemble, but the weight increases and vibration resistance deteriorates
Solution Approach 1:
The patent integrates the heat exchanger and expansion valve into a single unified component structure. The expansion valve is directly mounted on the heat exchanger body, eliminating the need for separate pipe connections. This merging of components reduces the overall assembly weight while improving vibration resistance through direct structural coupling rather than flexible pipe connections.
2Ease of manufacture
If the heat exchanger and expansion valve are connected by pipes, then the components can be manufactured separately, but the structural complexity increases and reliability decreases
Solution Approach 1:
The patent combines the heat exchanger and expansion valve into an integrated assembly where the valve body is directly mounted on the heat exchanger body through structural coupling. This eliminates the need for separate pipe connections, flanges, and mounting brackets, thereby reducing structural complexity while maintaining manufacturability through modular design of the integrated components.
3Ease of operation
If separate connections are used for sensor and valve component, then the sensor can be independently positioned, but the number of connections increases and structure becomes complex
Solution Approach 1:
The patent integrates the sensor mounting structure with the valve component assembly. The sensor is positioned and fixed relative to the valve body and heat exchanger body through the same structural coupling mechanism, eliminating the need for separate sensor mounting connections. This reduces the total number of connections while maintaining the sensor's ability to be independently positioned for optimal measurement.
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 reduces the number of connections and simplifies the structure, enhancing vibration resistance and facilitating easier installation while maintaining effective heat management for the battery system.
Implementation Method 1
The heat exchanger may generally be a dual-channel heat exchanger with two kinds of fluids flowing inside, which are respectively a refrigerant and a cooling liquid isolated from each other in the heat exchanger, and exchange heat in the heat exchanger
Implementation Method 2
A refrigerant enters the heat exchanger through a throttling effect of the expansion valve
Implementation Method 3
the sensor is capable of detecting a temperature and/or pressure of a working medium in the third flow channel
Data Source
AI summary
A heat management assembly includes a valve component and a heat exchange core body. The heat exchange core body and the valve component are fixedly connected by welding. The valve component further includes a sensor. The sensor is electrically connected to a circuit board. The sensor at least partially extends into a third flow channel. The sensor can measure the temperature and/or pressure of a working medium in the third flow channel. The heat exchange core body at least includes a positioning portion. A valve at least includes a matching portion. The positioning portion and the matching portion are provided to correspondingly match each other. The sensor, the valve component, and the heat exchange core body are integrally assembled to facilitate relative reduction of connections of pipelines and sensor lines, thereby facilitating structure simplification and facilitating mounting.