Integrated Refrigerant Module Bracket for Thermal Isolation
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Solution Overview
Problem
The existing thermal management systems in electric and hybrid vehicles face increased assembly processes and wiring complexity due to the separation of refrigerant modules and controllers, along with potential thermal conduction issues.
Innovation Solution
A refrigerant module assembly that integrates a refrigerant module and a controller using a mounting bracket, allowing them to be mounted together in the vehicle body, reducing assembly processes and wiring complexity while maintaining spatial efficiency and preventing thermal conduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the refrigerant module and controller are mounted separately in the vehicle body, then thermal conduction from the high-temperature refrigerant module can be prevented, but the number of assembling processes increases and wiring complexity increases
Solution Approach 1:
The mounting bracket integrates multiple functions: it mechanically couples the refrigerant module and controller together while maintaining thermal isolation through its structure, and provides integrated wiring pathways. This merging of mounting, thermal management, and electrical connection functions into a single component resolves the contradiction by reducing assembly complexity while preserving thermal separation.
Solution Approach 2:
The mounting bracket acts as an intermediary component between the refrigerant module and controller, providing both mechanical support and thermal isolation. The bracket's structure includes thermal breaks or insulating features that prevent direct thermal conduction while enabling close proximity mounting, thus reducing wiring length without compromising thermal management.
2Device complexity
If the refrigerant module and controller are integrated using a mounting bracket, then the number of assembling processes is reduced and wiring is shortened, but thermal conduction may occur due to close proximity
Solution Approach 1:
The mounting bracket merges mechanical coupling with thermal isolation features into a single integrated component. The bracket includes built-in thermal breaks, insulating materials, or geometric features that disrupt heat flow paths, allowing the refrigerant module and controller to be mounted in close proximity without significant thermal conduction.
Solution Approach 2:
The mounting bracket exhibits local quality variations with different thermal conductivity regions: areas in contact with the refrigerant module and controller use thermally isolating materials or structures, while other portions may use higher-strength materials for mechanical support. This localized differentiation of thermal properties enables close mounting while preventing thermal conduction.
3Adaptability or versatility
If components are modularized and connected by pipes, then the thermal management system can be flexibly configured, but the number of assembling processes increases
Solution Approach 1:
The mounting bracket merges mechanical mounting, thermal management, and electrical connection functions into a single integrated component. This consolidation reduces the number of separate assembly steps while preserving the modular flexibility of the thermal management system, as the bracket itself can be designed in different configurations to accommodate various component arrangements.
Data Source
AI summary
A refrigerant module assembly according to an embodiment may include a refrigerant module in which a refrigerant performs heat exchange while flowing, a controller configured to control a valve and a sensor provided in the refrigerant module, and a mounting bracket coupled to the refrigerant module and the controller and configured to mount the refrigerant module and the controller in a vehicle body.