Modular Thermal Management Assembly With Independent Coolant Loops
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Solution Overview
Problem
The thermal management system of electric vehicles is complex, requiring multiple components that occupy valuable space, add weight, and increase assembly time and cost, with challenges in regulating temperature and preventing thermal runaway.
Innovation Solution
A modular thermal management module that integrates coolant pumps, valves, and heat exchangers into a single unit, featuring independent coolant loops for different temperature regimes, with a countermeasure for thermal runaway using coolant flooding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If multiple thermal management components are integrated into a single modular unit, then assembly time and installation complexity are reduced, but the device complexity increases due to the integration of multiple subsystems
Solution Approach 1:
The patent integrates multiple thermal management components including coolant pumps, valves, heat exchangers, and control systems into a single modular unit. This consolidation reduces the number of separate assemblies required during installation, directly decreasing assembly time while managing complexity through standardized integration interfaces and modular architecture.
Solution Approach 2:
The modular thermal management unit is designed to perform multiple functions simultaneously - cooling the battery pack, cooling the motor, and potentially heating the cabin - all within a single integrated module. This multi-functionality reduces the need for separate dedicated systems for each function, thereby reducing overall assembly time and installation complexity.
2Manufacturing precision
If independent coolant loops are used for different temperature regimes, then temperature regulation precision is improved, but the device complexity increases due to multiple separate cooling circuits
Solution Approach 1:
The thermal management system is divided into separate independent coolant loops, each dedicated to specific temperature regimes. For example, one loop is dedicated to cooling the battery pack while another handles motor cooling. This segmentation allows each loop to be optimized for its specific temperature requirements, improving temperature regulation precision while containing complexity within manageable modular sections.
Solution Approach 2:
Each coolant loop is designed with local quality characteristics tailored to its specific function - different flow rates, heat exchanger configurations, and temperature ranges are optimized for each component's thermal management needs. This localized optimization enables precise temperature control for each subsystem while maintaining overall system modularity.
3Adaptability or versatility
If the thermal management system uses multiple separate components, then the adaptability to different temperature requirements is improved, but the weight and space occupation increase
Solution Approach 1:
Multiple thermal management components that would traditionally be separate - pumps, valves, heat exchangers, and control units - are merged into a single integrated modular unit. This consolidation reduces the total weight compared to having separate mounted components, while the modular design maintains the adaptability to handle different temperature regimes through its multi-loop architecture.
Solution Approach 2:
The modular thermal management unit is designed as a universal system that can handle multiple temperature regimes and cooling/heating requirements through its integrated multi-loop design. This universality allows a single module to replace what would otherwise require multiple separate systems, thereby reducing total weight and space occupation while maintaining full adaptability to different thermal management needs.
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
Facilitates efficient temperature regulation and rapid installation, reduces assembly time and cost, and prevents thermal runaway by detecting battery failures and flooding affected cells with coolant.
Implementation Method 1
A conjoined second compartment may include one or more of a valve actuator, an electronic control module, a system pressure sensor, a temperature sensor, and a heat exchanger
Implementation Method 2
The thermal management heat transfer medium is typically a fluid and is often a mixture of water and ethylene glycol in an appropriate ratio
Implementation Method 3
A conjoined second compartment may include one or more of a valve actuator, an electronic control module, a system pressure sensor, a temperature sensor
Data Source
AI summary
A thermal management module includes a first compartment including one or more of a coolant pump, a coolant valve, and a coolant conduit. A conjoined second compartment includes one or more of a valve actuator, an electronic control module, a system pressure sensor, a temperature sensor, and a heat exchanger. In certain embodiments, the first compartment is enclosed in a first modular enclosure and the conjoined second compartment is separately enclosed within a second modular enclosure.