Multi-Port Rotary Disc Valve for Multi-Loop EV Coolant Routing
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Solution Overview
Problem
The complexity of thermal management systems in electric vehicles, due to the number of vehicle components that need to be cooled, results in multiple coolant loops and corresponding pumps and valves, increasing costs, reducing efficiency, and affecting reliability.
Innovation Solution
A single multi-port rotary disc valve is used to distribute automotive coolant through various coolant loops, allowing a single valve-and-actuator assembly to manage multiple coolant streams, thereby reducing the complexity of the thermal management system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple coolant loops with multiple valves and pumps are used to cool various vehicle components, then the thermal management capability is improved, but the system complexity increases
Solution Approach 1:
The patent combines multiple coolant loop control functions into a single multi-port rotary valve assembly. The valve housing integrates multiple valve ports (P1-P8) that connect to different coolant loops, and the rotatable diverter assembly with multiple pockets can direct coolant flow to various destinations simultaneously. This merging of multiple valves into one unit reduces system complexity while maintaining the capability to manage multiple coolant loops.
Solution Approach 2:
The rotary valve assembly performs multiple functions: it controls flow direction for multiple coolant loops, switches between different coolant streams, and regulates thermal energy distribution to various vehicle components. The single valve-and-actuator assembly replaces what would traditionally require multiple separate valves, making the system more versatile while reducing component count.
2Adaptability or versatility
If multiple valves and pumps are used in the thermal management system, then the cooling coverage is improved, but the system cost increases
Solution Approach 1:
The patent merges multiple valve functions into a single integrated valve housing with multiple ports and a rotatable diverter assembly. By consolidating what would be multiple separate valve components into one unit, the system reduces part count, simplifies assembly, and lowers manufacturing costs while maintaining comprehensive cooling coverage for multiple vehicle components.
3Adaptability or versatility
If multiple valves and pumps are used to manage coolant flow, then the thermal control flexibility is improved, but the energy consumption increases
Solution Approach 1:
The patent combines multiple valve control functions into a single valve-and-actuator assembly. Instead of requiring multiple actuators to control separate valves, one actuator rotates the diverter assembly to control flow across multiple coolant loops simultaneously. This reduces the total number of moving parts and energy-consuming components while maintaining flexible thermal control capability.
4Manufacturing precision
If multiple valves are used in the thermal management system, then the flow control precision is improved, but the system reliability decreases
Solution Approach 1:
The patent integrates multiple flow control functions into a single valve housing with a rotatable diverter assembly. By reducing the number of separate valve components and connections, the system minimizes potential failure points such as leaks between components and connection failures. The integrated design maintains flow control precision through the multi-pocket diverter mechanism while improving overall system reliability.
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 use of a multi-port rotary disc valve simplifies the thermal management system, reduces energy consumption, lowers system costs, and enhances reliability by minimizing the number of valves and pumps required.
Implementation Method 1
at least one of the first pocket and the second pocket is configured to receive fluid flow directed in a first direction that is parallel to the rotational axis, and to reflect the received fluid flow in a second direction that is parallel to the rotational axis and opposite the first direction
Data Source
AI summary
A multi-port rotary disc valve includes a valve housing and a diverter assembly disposed in the housing. The housing includes a sidewall, a lid that closes a first end of the sidewall and a base that is disposed at a second end of the sidewall. The diverter assembly is configured to control fluid flow through the valve housing and includes a lid-facing surface, a base-facing surface, and diverter through openings that extend between the lid-facing surface and the base-facing surface. The diverter assembly includes a first pocket that opens toward the lid and a second pocket that opens toward the base. Each of the first pocket and the second pocket may receive fluid flow directed in a first direction that is parallel to the diverter rotational axis and to reflect the received fluid flow in a second direction that is opposite the first direction.