Thermal management integrated module

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Solution Overview

Problem

Existing thermal management integrated modules are large and not compact due to the horizontal mounting of the compressor and the lack of efficient space utilization.

Innovation Solution

A thermal management integrated module design with a compressor and flow channel plates having different orientations, allowing for a staggered mounting configuration that maximizes space utilization and reduces module size.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple separate components are used for the holder body, holder cover, and flow channel plate, then assembly flexibility is improved, but the number of parts increases and assembly complexity worsens

Engineering Contradiction:

Improveassembly flexibilityVSAvoidnumber of parts

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The holder body and flow channel plate are merged into a single integrated component. The flow channel plate is formed as an integral part of the holder body through injection molding, eliminating the need for separate assembly of these two components while maintaining their individual functional characteristics

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated holder body serves multiple functions simultaneously: it provides structural support as a holder, contains the flow channels for refrigerant circulation, and integrates the cover formation. This multi-functional design reduces the total number of parts needed in the compressor assembly

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of manufacture

If multiple separate components are used for the holder body, holder cover, and flow channel plate, then manufacturing flexibility is improved, but assembly time increases

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidassembly time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The holder body and flow channel plate are merged into a single integrated component that is manufactured in one injection molding process. This eliminates the need for separate assembly operations, reducing assembly time while maintaining manufacturing flexibility through mold design variations

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The flow channel plate is pre-formed as an integral part of the holder body during the injection molding process itself. The cooling channels are created within the mold cavity, so the flow path structure is already in place before the component is assembled to the compressor, eliminating subsequent assembly steps

Inventive Principle:

Principle #10Preliminary action

3Device complexity

If the holder body and flow channel plate are integrated, then the number of parts is reduced and assembly is simplified, but manufacturing difficulty increases

Engineering Contradiction:

Improvenumber of partsVSAvoidmanufacturing difficulty

Core Design Contradiction:

Device complexityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The manufacturing approach changes from assembling multiple metal or plastic components to a single injection molding process. By changing the manufacturing parameter from mechanical assembly to polymer processing, the integrated structure is achieved more efficiently, as injection molding can easily incorporate complex internal geometries like cooling channels

Inventive Principle:

Principle #35Parameter changes

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 design results in a smaller, more compact thermal management integrated module that optimizes space usage and enhances integration and mounting stability.

Implementation Method 1

the flow channel plate integrally formed with the holder body... directing refrigerant flow through integrated cooling channels

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentEP4410574B1Thermal management integrated module

Publication Date: 2026.04.15 ZHEJIANG SANHUA INTELLIGENT CONTROLS CO LTD

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AI summary

A thermal management integrated module includes a compressor, a first flow channel plate and a compressor bracket. The first flow channel plate includes a body portion and a connecting portion. At least one flow channel is provided in the body portion. The body portion and the connecting portion are of a one-piece configuration. The compressor bracket includes a first mounting portion and a second mounting portion. The first mounting portion and the second mounting portion have different orientations. The compressor is connected to the first mounting portion. The connecting portion is connected to the second mounting portion.