Multi-Port Valve Modes for Simplified EV Coolant Routing

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Solution Overview

Problem

Prior thermal system designs for electric vehicles are complex and costly due to the need for multiple fluid paths and valves to manage both heating and cooling requirements across various components, leading to a high rate of failure.

Innovation Solution

A multi-port, multi-mode valve that uses a single actuator to selectively open or close fluid flow between selected pairs of ports, allowing for various operational modes such as parallel and series configurations, thereby simplifying the routing of coolant between thermal loops without affecting other fluid paths.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple differing valves and routing paths are used to service heating and cooling needs, then the thermal system can meet diverse component requirements, but the system complexity increases and reliability decreases

Engineering Contradiction:

Improveability to service heating and cooling needsVSAvoidnumber of valves and routing paths

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

A single multi-port valve is designed to perform multiple functions that previously required separate valves. The valve body includes multiple ports and internal passages that can connect different combinations of ports through a single rotating mechanism, enabling one valve to replace multiple differing valves while maintaining the ability to service both heating and cooling needs of various components

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If multiple differing valves and routing paths are used to service heating and cooling needs, then the thermal system can meet diverse component requirements, but the cost increases

Engineering Contradiction:

Improveability to service heating and cooling needsVSAvoidsystem cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

Multiple separate valves and routing components are merged into a single integrated multi-port valve assembly. The valve body consolidates multiple flow paths and connection points into one component, reducing the total number of parts, simplifying manufacturing, and lowering system cost while maintaining the versatility to service both heating and cooling requirements

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If multiple differing valves and routing paths are used to service heating and cooling needs, then the thermal system can meet diverse component requirements, but the failure rate increases

Engineering Contradiction:

Improveability to service heating and cooling needsVSAvoidsystem failure rate

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

By designing a single multi-port valve to perform multiple functions, the number of potential failure points is reduced. The unified valve design with its single rotating mechanism and integrated sealing system replaces multiple separate valves, thereby lowering the overall failure rate while maintaining the system's ability to meet diverse heating and cooling requirements

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentEP3384187B1Multi-port valve with multiple operation modes

Publication Date: 2023.08.30 TESLA INC

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AI summary

A multi-port, multi-mode valve includes: a valve housing; multiple ports on the valve housing, a spacing between first and second ports being smaller than a spacing between third and fourth ports; and a stemshell positioned at least partly inside the valve housing, the stemshell having at least two channels configured for selectively coupling one or more of the ports to a selected at least other one of the ports.