Integrated Cooling Plate Layout for Compact EV Thermal Management
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Solution Overview
Problem
Conventional electric vehicle thermal management systems require numerous thermal management components that are dispersed, leading to increased space, weight, and cost due to the use of many cooling hoses and tubes, complicating assembly and increasing power consumption.
Innovation Solution
A multi-channel cooling pipeline integration apparatus in a rectangular plate shape with integrated cooling connection pipelines, component mounting points, and connection ports, allowing for compact arrangement and integration of thermal management components without hoses or tubes, optimizing layout and reducing flow resistance and heat leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple thermal management components are dispersed and connected using many cooling hoses or nylon tubes, then each component can be independently designed and assembled, but the system occupies large arrangement space, increases weight, and raises costs
Solution Approach 1:
The patent merges multiple thermal management components (expansion tank, cooling water pumps, heat exchanger, condenser, solenoid valves, temperature sensors) and their connection pipelines into a single integrated assembly. The integration apparatus includes a housing with internally formed cooling connection pipelines that directly connect all components, eliminating the need for separate hoses and tubes. This combining approach reduces system weight while maintaining component functionality.
Solution Approach 2:
The integration apparatus serves multiple functions simultaneously: it acts as the housing structure, provides the cooling connection pipelines, serves as the mounting platform for all thermal management components, and facilitates fluid flow between components. This multi-functionality reduces the number of separate parts needed, thereby reducing overall system weight.
2Adaptability or versatility
If multiple thermal management components are dispersed and connected using many cooling hoses or nylon tubes, then each component can be independently designed and assembled, but the system requires large arrangement space
Solution Approach 1:
The patent merges multiple thermal management components (expansion tank, cooling water pumps, heat exchanger, condenser, solenoid valves, temperature sensors) and their connection pipelines into a single integrated assembly. The integration apparatus includes a housing with internally formed cooling connection pipelines that directly connect all components, eliminating the need for separate hoses and tubes. This combining approach reduces system weight while maintaining component functionality.
Solution Approach 2:
The patent implements a nested structure where thermal management components are mounted inside or on the housing that contains the cooling connection pipelines. The pipelines are nested within the housing structure, and components are arranged in a compact configuration where smaller components can be positioned within the spatial envelope of larger components, maximizing space utilization.
3Adaptability or versatility
If multiple thermal management components are dispersed and connected using many cooling hoses or nylon tubes, then system flexibility is maintained, but manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The patent merges multiple thermal management components (expansion tank, cooling water pumps, heat exchanger, condenser, solenoid valves, temperature sensors) and their connection pipelines into a single integrated assembly. The integration apparatus includes a housing with internally formed cooling connection pipelines that directly connect all components, eliminating the need for separate hoses and tubes. This combining approach reduces system weight while maintaining component functionality.
Solution Approach 2:
The cooling connection pipelines are pre-formed as integral parts of the housing structure during the housing manufacturing process, rather than being assembled separately. Component mounting positions and connection ports are pre-configured in the housing, allowing components to be directly mounted and connected without complex assembly steps. This preliminary action simplifies the overall manufacturing and assembly process.
Data Source
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AI summary
A multi-channel cooling pipeline integration apparatus, a thermal management integration module, and an electric vehicle are provided, which belong to the field of vehicle technologies. The multi-channel cooling pipeline integration apparatus is in a substantially rectangular plate shape, and has a plurality of cooling connection pipelines formed therein. A plurality of component mounting points and a plurality of component connection ports are disposed on a surface of the multi-channel cooling pipeline integration apparatus. The plurality of component mounting points is configured to have at least two thermal management components mounted thereon. Each of the plurality of component connection ports is in communication with a corresponding one of the plurality of cooling connection pipelines, to enable the at least two thermal management components mounted on the plurality of component mounting points to be connected, through the plurality of component connection ports, to the plurality of cooling connection pipelines. The at least two thermal management components are configured to be connected to each other through the plurality of cooling connection pipelines. The multi-channel cooling pipeline integration apparatus can serve as both a connection channel and a carrier member to integrate thermal management components without using a large number of cooling rubber hoses or nylon tubes, saving costs and an arrangement space of a thermal management system and achieving lightweight of a whole vehicle.