Modular Thermal Management Coolant Valves and Pumps
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Solution Overview
Problem
The complexity and criticality of liquid cooling systems in electric and hybrid-electric vehicles pose challenges in maintaining temperature control for sensitive components, necessitating redundant systems and increased complexity, which can lead to safety issues if not properly managed.
Innovation Solution
A modular thermal management system utilizing a combination of three-way and four-way valves, pressure/temperature sensors, and a pump to route coolant through multiple loops, allowing for efficient temperature regulation and redundancy in cooling paths, ensuring effective heat management across various vehicle components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a liquid cooling system is designed with multiple pumps, valves, and sensors to ensure proper cooling of temperature-sensitive components, then the reliability of thermal management is improved, but the device complexity increases significantly
Solution Approach 1:
The patent combines multiple cooling circuits into a single integrated liquid cooling system with a common pump and coolant distribution manifold. The manifold distributes coolant to multiple circuits (battery cooling circuit, motor cooling circuit, etc.) through integrated valve assemblies, reducing the need for separate pumps and complex routing while maintaining reliable thermal management across all temperature-sensitive components.
Solution Approach 2:
The common pump serves multiple cooling circuits simultaneously, and the coolant distribution manifold provides universal coolant delivery to various temperature-sensitive components. The valve assemblies are designed to control flow to multiple circuits from a single integration point, allowing one component to perform multiple functions and reduce overall system complexity.
2Reliability
If redundant cooling paths are built into the system to ensure proper operation, then the safety and reliability are improved, but the device complexity and number of components increase
Solution Approach 1:
The patent integrates multiple cooling circuits into a unified system where a single pump and manifold provide redundant cooling paths to temperature-sensitive components. The integrated valve assemblies allow flexible routing of coolant through different circuits, providing redundancy without requiring completely separate backup systems, thus maintaining reliability while controlling complexity.
3Adaptability or versatility
If multiple separate cooling circuits are used for different temperature-sensitive components, then the adaptability of thermal management is improved, but the device complexity and number of connections increase
Solution Approach 1:
The coolant distribution manifold is designed to serve multiple cooling circuits (battery, motor, inverter) from a single integration point. The integrated valve assemblies can direct coolant flow to different circuits as needed, providing adaptability for various thermal management scenarios while reducing the number of separate connections and components compared to fully independent circuits.
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
The system provides robust and efficient thermal management by dynamically routing coolant through different loops, maintaining component temperatures within operational limits and reducing the risk of component failure, thereby enhancing vehicle safety and reliability.
Implementation Method 1
A modular thermal management system utilizing a combination of three-way and four-way valves, pressure/temperature sensors, and a pump to route coolant through multiple loops
Implementation Method 2
Liquid cooling systems transfer thermal energy to, from, and/or between the batteries, motors, inverters, and other temperature-sensitive vehicle components and the vehicle's heat exchangers
Implementation Method 3
pressure/temperature sensors
Implementation Method 4
pressure/temperature sensors
Data Source
AI summary
A thermal management device for use in a vehicular or other thermal management circuit utilizes a pump, one or more valves, and one or more pressure/temperature sensors to route coolant through different desired flow paths and maintain components within the thermal circuit at appropriate temperatures.