Integrated Channel Layout for EV Thermal System Heat Pump Upgrades
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Solution Overview
Problem
Existing electric vehicles require separate design and manufacturing for heat pump and non-heat pump thermal management systems, leading to increased costs and weight when upgrading from non-heat pump to heat pump systems.
Innovation Solution
An integrated channel apparatus for non-heat pump thermal management modules, featuring a first component with channels and grooves, and a second component with strip grooves, allowing for quick disassembly and adaptation with valves to form a nine-way valve system suitable for heat pump management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate design and manufacturing are used for heat pump and non-heat pump thermal management systems, then system functionality is ensured, but vehicle cost and weight increase when upgrading from non-heat pump to heat pump systems
Solution Approach 1:
The pipeline interface is designed with a universal structure that can accommodate both non-heat pump and heat pump system configurations. The interface includes multiple connecting tubes with standardized dimensions and mounting positions, allowing the same physical interface to serve different thermal management modes without requiring separate hardware designs.
Solution Approach 2:
The pipeline interface is divided into modular components including a body, cover, and multiple independently configurable connecting tubes. This segmentation allows selective activation or deactivation of specific tubes depending on whether the system operates in non-heat pump or heat pump mode, enabling upgradeability without replacing the entire interface assembly.
2Adaptability or versatility
If separate design and manufacturing are used for heat pump and non-heat pump thermal management systems, then system functionality is ensured, but vehicle cost increases when upgrading from non-heat pump to heat pump systems
Solution Approach 1:
The pipeline interface uses a universal design that can be manufactured as a single standardized component for all vehicle platforms, whether equipped with heat pump or non-heat pump systems initially. This reduces tooling costs, simplifies supply chain management, and eliminates the need for expensive platform-specific manufacturing processes.
Solution Approach 2:
The pipeline interface is pre-designed and pre-manufactured with all necessary mounting features, sealing surfaces, and connecting tube positions for future heat pump system integration. This preliminary preparation allows manufacturers to produce the interface once with full upgrade capability built-in, rather than requiring costly retrofits or additional manufacturing steps later.
3Adaptability or versatility
If the same pipeline interface is used for both heat pump and non-heat pump systems, then platform universality is achieved, but vehicle weight increases due to additional components
Solution Approach 1:
The pipeline interface merges the requirements of both heat pump and non-heat pump systems into a single integrated component. The body and cover are designed to accommodate all necessary connecting tubes and mounting features for both system types, eliminating the need for separate interface assemblies and reducing overall weight compared to having duplicate hardware.
Solution Approach 2:
The pipeline interface incorporates dynamic configurability through selectively activatable connecting tubes and adjustable mounting positions. This allows the physical interface to adapt its functional configuration based on system requirements, providing platform universality without the weight penalty of permanently installed unused components.
4Adaptability or versatility
If the same pipeline interface is used for both heat pump and non-heat pump systems, then platform universality is achieved, but vehicle cost increases
Solution Approach 1:
The pipeline interface serves as a universal component that can be manufactured using the same processes, tools, and quality standards for all vehicle platforms. This eliminates the need for maintaining separate manufacturing lines or tooling for heat pump and non-heat pump variants, significantly reducing setup costs and achieving economies of scale.
Solution Approach 2:
The pipeline interface is pre-engineered with all necessary features for both heat pump and non-heat pump configurations, allowing it to be manufactured once and deployed across multiple platforms. This preliminary design action eliminates the need for costly platform-specific tooling investments and reduces manufacturing complexity.
Data Source
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AI summary
The present invention relates to a technical field of an electric vehicle, in particular to an integrated channel apparatus for a non-heat pump thermal management integrated module and an electric vehicle. The integrated channel apparatus includes a first component and a second component, the first component is provided with a channel group that runs through the first component along a thickness direction and a groove that does not run through the first component, the channel group and the groove are used to accommodate a connecting tube. The second component is provided with multiple strip grooves, each strip groove is provided corresponding to two channels to connect the two channels. During use, the integrated channel apparatus is installed in the non-heat pump thermal management integrated module, and the connecting tubes that need to be connected are placed in the two channels and the strip groove correspondingly connecting the two channels; when being upgraded to a heat pump management system, the integrated channel apparatus is disassembled, and a three-way valve or a four-way valve is installed on the connecting tube. It is possible to quickly upgrade the electric vehicle from the non-heat pump system to the heat pump system without significantly increasing the cost and weight of the entire vehicle.