Integrated Valve-Pump Module for Low-Pressure-Loss Coolant Flow
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Solution Overview
Problem
Existing thermal management systems for electric vehicles are complex, involve numerous components such as valves and pumps, leading to assembly complications and high pressure drops.
Innovation Solution
A combined valve-and-pump module with a single housing that integrates a valve member, actuator, pump impeller, and driver, featuring a rotatable valve member and axial flux motor to control coolant flow, reducing the number of components and pressure drops.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate valves and pumps are used in thermal management systems, then flow control and coolant circulation can be achieved, but device complexity and assembly difficulty increase
Solution Approach 1:
The patent combines a valve assembly and pump assembly into a single integrated module housing. The valve member with flow control apertures and the pump impeller with drive shaft are positioned within the same housing and share common fluid passages, eliminating the need for separate valve and pump components while maintaining independent flow control and coolant circulation functions.
2Adaptability or versatility
If multiple separate components are used, then functional capabilities are achieved, but assembly complications arise
Solution Approach 1:
The valve member and pump impeller are integrated within a single modular housing that can be manufactured as one unit or pre-assembled together. This integration reduces the number of separate assembly steps required in the thermal management system, as the entire valve-and-pump assembly can be installed as a single module rather than assembling multiple separate components.
3Ease of operation
If multiple valves and pumps are used, then coolant flow control is achieved, but pressure drops increase
Solution Approach 1:
The valve and pump are positioned in close proximity within the same housing, allowing coolant to flow directly from the pump outlet to the valve inlet through short internal passages. This integration minimizes the total length of coolant pathways and reduces the number of external connections and seals required, thereby reducing pressure drops and energy losses in the coolant circulation system.
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
Simplifies assembly, reduces component count, and minimizes pressure loss in the coolant system, enhancing reliability and efficiency.
Implementation Method 1
The pump driver includes an axial flux motor including a stator that is connected to the valve-and-pump module housing, and a rotor that is connected to and coaxial with the pump impeller. The rotor is rotatable by energizing the stator, to drive rotation of the pump impeller.
Implementation Method 2
The valve member is rotatable about a valve member axis between a first position in which the at least one pass-through aperture fluidically connects the plurality of valve inlets to the valve outlet in a first way to provide a first flow arrangement through the coolant transport system, and a second position in which the at least one pass-through aperture fluidically connects the plurality of valve inlets to the valve outlet in a second way to provide a second flow arrangement through the coolant transport system that is different than the first flow arrangement.
Implementation Method 3
The pump impeller is positioned in the pump chamber for rotation about a pump impeller axis that is coaxial with the valve member axis. The pump impeller is shaped so as to drive coolant from the pump inlet through the volute to the pump outlet.
Data Source
AI summary
In an aspect, a valve-and-pump module for controlling a flow of coolant in a thermal management system for a vehicle is provided. The valve-and-pump module includes a valve-and-pump module housing, a valve member, a valve actuator, a pump impeller and a pump driver.