Multi-Port Thermal Module With Rotary Flow Routing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current multi-port thermal modules for electric vehicles require an excessive number of actuators, rotors, and housings to achieve desired flow configurations, leading to undesirable packaging configurations and inefficiencies in thermal management.
Innovation Solution
A multi-port thermal module design that incorporates a central housing with integrated flow cavities, inner and outer housing portions, and a reduced number of actuators and valves, allowing for flexible flow configurations through the use of rotors that can be oriented to direct fluid between various flow paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple valve assemblies in various locations are used to achieve optimized thermal management, then thermal management capability is improved, but packaging configuration becomes undesirable
Solution Approach 1:
The patent combines multiple valve assemblies into a single integrated multi-port thermal module with a common inlet port and multiple outlet ports. This merging approach maintains the thermal management capability of multiple valves while reducing packaging complexity by consolidating what would have been separate assemblies into one unified structure.
Solution Approach 2:
The single multi-port valve assembly performs multiple functions that would traditionally require separate valve assemblies. The valve member can direct fluid to different outlet ports based on its orientation, providing versatile thermal management control for battery packs, motors, and other EV components through one integrated unit.
2Adaptability or versatility
If manifold style valves with multiple ports are used, then flow path options increase, but flexibility to accommodate different flow modes decreases
Solution Approach 1:
The valve member can be rotated to different orientations to dynamically change flow paths. This dynamic adjustment capability allows the system to accommodate different flow modes (such as heating, cooling, or bypass modes) by simply rotating the valve member to different positions, providing operational flexibility that static manifold designs cannot achieve.
Solution Approach 2:
The valve body is segmented into multiple ports with the valve member able to selectively connect different combinations. This segmentation allows independent control of fluid flow to different outlets while maintaining a compact single-unit structure, resolving the contradiction between having multiple flow path options and maintaining operational flexibility.
3Device complexity
If three-port and four-port valves with single valve members are used, then valve count is reduced, but ability to accommodate complex flow configurations decreases
Solution Approach 1:
The invention adds rotational dimensionality to the valve member, allowing it to be oriented at different angles to create various flow configurations. This dimensional change transforms a simple single-port valve into a multi-functional device that can accommodate complex flow patterns (such as series, parallel, or independent flow paths) that would otherwise require multiple separate valves.
Solution Approach 2:
The patent integrates multiple flow path capabilities within a single valve assembly structure. The valve member can be nested in different rotational positions within the valve body, with each position enabling different flow configurations. This nesting approach allows complex flow capabilities to be contained within a single compact unit rather than requiring multiple external valves.
Data Source
AI summary
A multi-port thermal module which includes a central housing, a plurality of flow cavities integrally formed as part of the central housing, at least one inner housing connected to a first side of the central housing, a first plurality of inner flow channels integrally formed as part of the first inner housing, each of the first plurality of inner flow channels in fluid communication with at least one of the flow cavities, and a first outer housing connected to the first inner housing. A portion of each of a first plurality of flow channels is integrally formed as part of the first inner housing, and another portion of each of the first plurality of flow channels is integrally formed as part of the first outer housing. A rotor located in the central housing is rotated to various orientations to direct fluid between the plurality of flow cavities.