Rectangular Convoluted Coolant Tube for Tight EV Chassis Routing
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Solution Overview
Problem
In electric vehicle thermal management systems, round coolant tubes require large diameters and consume high power due to pressure drops, making them inefficient for narrow and irregular spaces within the vehicle chassis.
Innovation Solution
A rectangular fluid tube with a convoluted section is designed, featuring a series of peaks and valleys that allows for flexible navigation through confined spaces while maintaining a compact profile, reducing power requirements by optimizing the tube's cross-sectional shape and material composition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If round tubes are used to convey coolant fluid, then adequate fluid flow is achieved, but large space requirements and high weight result
Solution Approach 1:
The patent changes the cross-sectional shape parameter from circular to rectangular, allowing the tube to maintain adequate fluid flow capacity while reducing outer dimensions. The rectangular shape with optimized aspect ratio provides sufficient hydraulic diameter for coolant flow while reducing the tube's footprint and weight in vehicle applications.
Solution Approach 2:
The patent introduces convoluted sections with peaks and valleys that add dimensional complexity to the tube structure. This allows the tube to navigate three-dimensional space more efficiently, fitting into narrow and irregular spaces within the vehicle chassis while maintaining fluid flow capacity through the rectangular cross-section.
2Quantity of substance
If round tubes with large internal diameters are used, then adequate fluid flow is achieved, but space requirements increase
Solution Approach 1:
The patent changes the cross-sectional geometry from circular to rectangular, allowing optimization of the hydraulic diameter while reducing the outer footprint. The rectangular shape enables better space utilization in confined areas, providing adequate fluid flow capacity through optimized internal dimensions while minimizing the space occupied by the tube assembly in the vehicle.
Solution Approach 2:
The patent incorporates convoluted sections with curved peaks and valleys that allow the tube to bend and navigate around obstacles in confined spaces. This curvature enables the tube to fit into irregular three-dimensional spaces while maintaining the rectangular cross-section that provides efficient fluid flow capacity.
3Quantity of substance
If round tubes are used in thermal management systems, then fluid conveyance is achieved, but pressure drops increase power consumption
Solution Approach 1:
The patent changes the cross-sectional shape to rectangular with optimized dimensions that reduce pressure drops in the coolant flow. The rectangular shape with appropriate aspect ratio improves flow characteristics and reduces turbulence, thereby lowering the pressure differential required to convey coolant through the thermal management system and reducing pump power consumption.
4Adaptability or versatility
If convoluted sections are added to tubes, then space flexibility is improved, but manufacturing complexity increases
Solution Approach 1:
The patent segments the tube into distinct sections: straight sections with rectangular cross-sections and convoluted sections with peaks and valleys. This segmentation allows each section to be optimized independently for its function while simplifying the overall manufacturing process through modular construction and assembly.
Data Source
AI summary
A rectangular tube is disclosed comprising a rectangular convoluted section that includes a wall that defines a series of peaks alternating with a series of valleys and that provides a periphery of opposing rectangular base sides and opposing rectangular height sides. A continuous rectangular section extends from one end of the rectangular convoluted section and a transition section extends from another end of rectangular convoluted section.