Integrated Coolant Tank Housing for EV Thermal Circuit Simplification
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Solution Overview
Problem
Electric vehicles require complex cooling systems with multiple separate coolant circuits to manage motor heat, battery temperature, and passenger compartment temperature, leading to increased manufacturing difficulty, thermal bridges, and reduced volume capacity in coolant tanks.
Innovation Solution
A coolant tank design where the outer wall serves as the first electronics housing part, sealing tank electronics with a second housing part, allowing for reduced component parts, simplified assembly, and centralized control of the coolant conducting system, with integrated signal-transmitting connections and a multipart tank housing for efficient space use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate coolant circuits are implemented to manage motor heat, battery temperature, and passenger compartment temperature, then temperature regulation capability is improved, but device complexity increases
Solution Approach 1:
The coolant tank is designed as a multi-functional component that serves both as a coolant storage reservoir and as an electronics housing. The tank contains integrated cooling channels that can distribute coolant to multiple circuits (motor cooling, battery cooling, passenger compartment heating), allowing a single component to perform multiple functions and reduce overall system complexity.
Solution Approach 2:
The patent combines the coolant tank and electronics housing into a single integrated component. The electronics housing is formed as part of the tank structure, with the tank wall itself serving as one side of the housing. This merging eliminates the need for separate mounting brackets, fasteners, and sealing components, thereby reducing device complexity while maintaining the capability to manage multiple coolant circuits.
2Volume of moving object
If device components are shifted into the interior of the coolant tank, then space efficiency is improved, but manufacturing difficulty increases
Solution Approach 1:
The tank and electronics housing are merged into a single integrated component formed in one manufacturing process. The housing is formed as an integral part of the tank wall structure, eliminating the need for separate assembly steps to install electronics components inside the tank. This approach maintains space efficiency while dramatically simplifying manufacturing.
Solution Approach 2:
The tank wall is designed to serve dual purposes: as the boundary of the coolant storage reservoir and as the housing structure for electronics. This multi-functionality is achieved through the integrated design where the outer wall of the tank forms the housing wall, eliminating the need for separate housing components and simplifying manufacturing.
3Device complexity
If the outer wall is designed as the first electronics housing part, then component parts are minimized, but sealing requirements increase
Solution Approach 1:
The tank and housing are merged into a single component, which inherently eliminates many sealing interfaces that would exist between separate parts. The integration reduces the number of sealing requirements while maintaining protection of electronics, as the unified structure has fewer joints and potential leak paths.
Data Source
AI summary
A coolant tank for a coolant conducting system of a motor vehicle, comprising a tank housing with an outer wall and an interior which is arranged in the tank housing for storing a coolant for the coolant conducting system. The outer wall is designed as a first electronic housing part for a tank electronic device, wherein the outer wall is designed such that the outer wall together with a second electronic housing part for the tank electronic device, the second electronic housing part being designed as an electronic housing cover, surrounds the tank electronic device so as to seal off same from environmental influences, thereby directly or indirectly using a seal.