Integrated Coolant Manifold for Dual EV Cooling Circuits

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Solution Overview

Problem

Existing electric vehicle cooling systems require separate reservoir tanks for PE components and batteries, leading to increased manufacturing costs, weight, and complexity due to the need for multiple components and assembly processes.

Innovation Solution

A coolant module with an integrated coolant manifold that combines a reservoir tank and coolant flow path, allowing for the mounting of heat exchange components and a coolant control module, thereby reducing the number of components and assembly processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate reservoir tanks are provided for PE components and battery cooling circuits, then each cooling circuit can operate independently, but the number of components increases, manufacturing costs increase, and assembly complexity increases

Engineering Contradiction:

Improveindependent cooling circuit operationVSAvoidnumber of reservoir tanks and components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges two separate reservoir tanks into a single integrated reservoir tank that serves both the PE component cooling circuit and the battery cooling circuit. This integration reduces the total number of components while maintaining the ability to independently control coolant flow to each cooling circuit through separate inlet/outlet ports and flow path branches.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated reservoir tank is designed with multi-functionality to serve dual purposes: it acts as the reservoir for both cooling circuits simultaneously and provides a common coolant supply point. The tank includes multiple outlet ports that can independently supply coolant to different cooling circuits, enabling one component to perform multiple functions that previously required separate components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If separate reservoir tanks are provided for PE components and battery, then each cooling circuit is independent, but the weight of the cooling system increases

Engineering Contradiction:

Improveseparate cooling circuitsVSAvoidweight of cooling system

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

By combining two separate reservoir tanks into one integrated unit, the patent eliminates the weight of one entire reservoir tank assembly. The merged design maintains separate cooling circuit functionality through internal flow path segmentation while reducing the total material used and overall system weight.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If two separate reservoir tanks are used, then each cooling circuit can be maintained separately, but manufacturing costs increase

Engineering Contradiction:

Improveseparate cooling circuit maintenanceVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The integration of two reservoir tanks into one reduces manufacturing costs by decreasing the total number of parts that need to be produced, inventoried, and assembled. The single integrated tank design simplifies the supply chain and manufacturing process while maintaining the functional separation of cooling circuits through internal flow path design.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The multi-functional reservoir tank design allows a single component to replace what would traditionally require two separate components, thereby reducing per-unit manufacturing costs while maintaining the ability to independently service and maintain each cooling circuit through dedicated access points and flow paths.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Reliability

If separate reservoir tanks are provided, then each cooling circuit is independent, but assembly time increases and productivity decreases

Engineering Contradiction:

Improveindependent cooling circuitsVSAvoidassembly time

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

By merging two separate reservoir tank installations into one integrated component, the patent reduces the number of assembly operations required. The integrated design allows both cooling circuits to be assembled and connected simultaneously rather than requiring separate assembly processes for each tank, thereby improving production efficiency and reducing assembly time.

Inventive Principle:

Principle #5Merging (Combining)

5Reliability

If separate reservoir tanks are used, then each cooling circuit can be maintained separately, but the number of hoses or pipes increases

Engineering Contradiction:

Improveseparate cooling circuit maintenanceVSAvoidnumber of hoses and pipes

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The integration of reservoir tanks eliminates the need for additional hoses or pipes that would connect separate tanks to their respective cooling circuits. The integrated design provides direct access to both cooling circuits from a single reservoir unit, reducing the total length and number of piping connections required while maintaining independent circuit functionality.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS20250153558A1Cooling water module comprising cooling water manifold

Publication Date: 2025.05.15 HANON SYST CO LTD

AI summary

The present invention relates to a coolant module including a coolant manifold applied to a vehicle, and more particularly, to a coolant module including a coolant manifold, in which the coolant manifold is configured by integrating a reservoir tank and a coolant flow path, and the coolant module is configured by mounting heat exchange components in the coolant manifold.