Integrated Thermal Management Module to Reduce Coupling Complexity
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Solution Overview
Problem
Existing thermal management systems for vehicles require complex and cumbersome connections between refrigerant and coolant circuits, making manufacturing, testing, and maintenance challenging due to the need for multiple fluid-tight seals and numerous couplings.
Innovation Solution
A modular thermal management system with an integrated module that includes an internal heat exchanger, evaporator, and accumulator, which are attached to a bracket, allowing for simplified connections and independent manufacturing, testing, and maintenance by configuring refrigerant and coolant flows through distinct paths within the module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple fluid conveying components are connected to form refrigerant and coolant circuits, then the thermal management system can perform heat exchange functions, but the number of fluid-tight seals and couplings increases, making the system complex and cumbersome
Solution Approach 1:
The patent combines multiple fluid conveying components (evaporator, condenser, expansion device, and coolant heat exchanger) into a single integrated thermal management module. This merging eliminates the need for multiple separate couplings and fluid-tight seals between these components, directly reducing system complexity while maintaining all necessary heat exchange functions.
Solution Approach 2:
The patent segments the thermal management system into a modular unit that can be independently manufactured and installed. By creating a self-contained module with integrated components, the system reduces the number of connection points with the rest of the vehicle's thermal management system, thereby reducing the overall number of couplings and seals required.
2Productivity
If multiple fluid conveying components are connected with fluid lines, then the thermal management system can operate, but manufacturing and maintenance become challenging due to numerous connections
Solution Approach 1:
By merging multiple fluid conveying components into a single integrated module, the patent eliminates the need for numerous fluid lines and connections that would complicate manufacturing and maintenance. The module can be manufactured as a complete unit and installed as one assembly, significantly simplifying both production processes and field maintenance.
Solution Approach 2:
The patent applies preliminary action by pre-assembling and pre-testing the thermal management module as a complete unit before installation in the vehicle. This allows manufacturing and quality testing to be completed on the integrated module rather than on individual components, reducing manufacturing complexity and making maintenance easier since the module can be replaced as a single unit if issues arise.
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 modular design reduces the complexity of connections, facilitates easier manufacturing and maintenance, and minimizes the number of couplings required, enhancing the efficiency and reliability of thermal management in vehicles.
Implementation Method 1
an internal heat exchanger attached to the bracket with the internal heat exchanger including a high-pressure side and a low-pressure side... a first flow of a refrigerant flowing through a first flow path of the module passing through the high-pressure side of the internal heat exchanger and a second flow of the refrigerant flowing through a second flow path of the module passing through... the low-pressure side of the internal heat exchanger
Implementation Method 2
a coolant circuit having a coolant flowing through the evaporator of the refrigerant circuit to exchange heat between the refrigerant and the coolant within the evaporator with the coolant in heat exchange communication with a heat generating component of the vehicle
Data Source
AI summary
A module of a thermal management system includes a bracket having an internal heat exchanger, an evaporator, and an accumulator attached thereto. The internal heat exchanger includes a high-pressure side and a low-pressure side. The module includes a first flow of a refrigerant flowing through a first flow path of the module passing through the high-pressure side of the internal heat exchanger, a second flow of the refrigerant flowing through a second flow path of the module passing through, in an order of the second flow, the evaporator, the accumulator, and the low-pressure side of the internal heat exchanger, and a flow of a coolant flowing through a third flow path of the module passing through the evaporator.