Modular Coolant Flow Control for Multi-Path EV Electronics Cooling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current valve designs for cooling electronic components in electric vehicles are limited in configuration, capacity, and complexity, making them costly and inefficient for managing coolant flow effectively.
Innovation Solution
A coolant flow control module with multiple valve modules, featuring rotors and actuators that allow for various orientations and fluid communication configurations, enabling flexible and efficient coolant flow management across multiple ports.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If current valve designs are used for cooling electronic components, then the valve structure is simple, but the cooling capacity and configuration flexibility are insufficient
Solution Approach 1:
The valve assembly is divided into multiple independent valve modules (first valve module, second valve module, third valve module), each capable of independent operation. This segmentation allows each module to be optimized for specific cooling paths while maintaining overall system flexibility, resolving the contradiction between adaptability and complexity by breaking down the complex multi-way valve into simpler, manageable units.
Solution Approach 2:
Each valve module is designed with universal functionality to handle multiple fluid paths and configurations. The modules can be assembled in different arrangements (series, parallel, or isolated) to create various cooling configurations, allowing the same basic module design to serve multiple cooling needs without requiring completely different valve designs for each application.
2Ease of manufacture
If current valve designs are used, then manufacturing cost is high, but the design is complex and costly to manufacture
Solution Approach 1:
By segmenting the valve into standardized modules, each module can be manufactured independently using the same processes and tools, achieving economies of scale. The modular design simplifies manufacturing by allowing repeatable production of identical units rather than custom manufacturing of complex integrated valves, directly reducing manufacturing cost while maintaining the ability to create complex cooling configurations.
Solution Approach 2:
The invention changes the fundamental parameter of valve architecture from integrated to modular. This parameter change enables standardization of components, simplification of manufacturing processes, and reduction of tooling costs, while the modular nature allows flexible assembly to meet different cooling requirements without increasing per-unit manufacturing complexity.
3Quantity of substance
If multiple valve modules are used to provide multiple flow paths, then cooling capacity is improved, but device complexity increases
Solution Approach 1:
The coolant flow capacity is increased by adding more valve modules in series or parallel arrangements, but each module remains a simple, standardized unit. This segmentation approach allows the system to scale coolant flow capacity linearly by adding modules without exponentially increasing the complexity of individual components, as each module handles a discrete portion of the total flow control.
Data Source
AI summary
A coolant flow control module, having a first outer housing, a first rotor located in the first outer housing, a second outer housing adjacent the first outer housing, and a second rotor disposed in the second outer housing. The second rotor is engaged with the first rotor such that the first rotor and second rotor rotate in unison. An actuator is connected to the first rotor, a first plurality of ports is integrally formed as part of the first outer housing, and a second plurality of ports is integrally formed as part of the second outer housing. The actuator rotates the first rotor and second rotor to at least one of a plurality of orientations such that fluid is able to flow through the first plurality of ports and the first rotor, and fluid is able to flow through the second plurality of ports and the second rotor.