Rotating Louver Thermal Control Valve for Compact EV Coolant Routing
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Solution Overview
Problem
The increasing demand for longer all-electric ranges in hybrid and battery-powered vehicles necessitates larger battery packs with higher thermal management demands, requiring more space-efficient and higher-capacity thermal management components that can control fluid flow effectively.
Innovation Solution
A thermal management control valve with a housing assembly and a louver plate assembly, featuring dual louver plates and seal assemblies, allows selective rotation to align fluid passageways and ports, providing efficient fluid communication while maintaining a compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional thermal management valves are used, then fluid flow control is provided, but the packaging size is large and space efficiency is low
Solution Approach 1:
The valve body is divided into a first section and a second section with separate fluid passageways, allowing independent flow control paths. The louver plate assembly is segmented with multiple louver plates that can be independently positioned, enabling compact integration of multiple flow control functions within a reduced overall volume.
Solution Approach 2:
The louver plate assembly is nested within the valve body housing, with louver plates positioned between the first and second valve sections. The seal assemblies are nested between the louver plates and valve sections, creating a compact layered structure that maximizes space utilization and reduces packaging size while maintaining full flow control capability.
2Power
If thermal management capacity is increased to meet higher demands, then heating and cooling capability is improved, but device volume increases
Solution Approach 1:
The valve assembly provides multiple fluid flow paths through the first and second valve sections, enabling it to serve multiple thermal management functions simultaneously. The separate passageways allow independent control of heating and cooling flows, increasing thermal management capacity without requiring separate valve components, thus avoiding volume increase.
Solution Approach 2:
The valve utilizes a layered three-dimensional arrangement with louver plates positioned between valve sections, creating efficient use of vertical and radial space. This dimensional optimization allows multiple flow paths to be packed into a compact cylindrical footprint, increasing thermal capacity while constraining volume growth.
Data Source
AI summary
A thermal management control valve a housing assembly having a first housing section and a second housing section, a rotary actuator coupled to a drive shaft, and a louver plate assembly. The louver plate assembly includes a louver plate having a louver cutout, a first seal assembly arranged between the louver plate and the first housing section, and a second seal assembly arranged between the louver plate and the second housing section. The first seal assembly includes a plurality of inner walls that define a plurality of first fluid passageways. The second seal assembly defines a second fluid passageway between. Selective rotation of the louver plate rotationally aligns the louver cutout with one or more of the plurality of first fluid passageways and the second fluid passageway to provide fluid communication between the one or more of the plurality of first fluid passageways and the second fluid passageway.