Integrated Thermal Management Unit for Vehicle Powertrain Fluids
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Solution Overview
Problem
Vehicle powertrains face challenges in efficiently regulating the temperature of fluids like coolant and transmission oil, leading to reduced fuel economy due to high viscosity at low temperatures, which requires rapid heating and waste heat rejection, and existing heat exchange systems are complex with many interconnections.
Innovation Solution
A thermal management unit integrating a valve and heat exchangers with a pressure relief valve and temperature-responsive elements to selectively route fluid through a transmission oil heater or cooler, using a shunt flow path to manage pressure and temperature, and a cast structure housing the components for compact installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a heat exchange system integrates multiple heat exchangers and flow control devices to regulate fluid temperature, then temperature regulation capability is improved, but system complexity increases
Solution Approach 1:
The patent integrates multiple heat exchangers (engine oil cooler, transmission oil cooler, coolant heater) and flow control devices into a single thermal management unit with a common housing. This merging approach maintains the temperature regulation capabilities for multiple fluids while reducing the number of separate components and interconnections required, thereby resolving the contradiction between adaptability and device complexity.
Solution Approach 2:
The thermal management unit is designed as a multi-functional system that can simultaneously or independently regulate temperatures of engine oil, transmission oil, and coolant. The integrated valve assembly can route fluids through different heat exchangers based on thermal management requirements, providing universal temperature control across multiple powertrain fluids within a single unit.
2Measurement precision
If multiple separate heat exchangers and control devices are used, then temperature control precision is improved, but ease of installation deteriorates
Solution Approach 1:
By combining multiple heat exchangers and control devices into one integrated thermal management unit, the patent maintains precise temperature control through dedicated heat exchange paths while significantly improving ease of installation. The unified structure requires fewer connections and simplifies the installation process compared to multiple separate components, directly addressing the contradiction between control precision and installation ease.
3Loss of time
If fluid is rapidly heated during cold startup, then warm-up time is reduced, but energy consumption increases
Solution Approach 1:
The integrated thermal management unit combines a coolant heater with engine oil and transmission oil coolers, allowing the system to rapidly warm up fluids during cold startup by routing them through the heater. After warmup, the same integrated structure enables efficient waste heat rejection. This merging of heating and cooling capabilities in one unit reduces warm-up time while managing energy consumption through coordinated thermal management of multiple fluids.
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
This solution enables efficient temperature regulation of vehicle powertrain fluids, reducing fuel consumption by facilitating rapid warm-up and maintaining optimal viscosity, while simplifying system installation and reducing interconnections.
Implementation Method 1
an integrated transmission oil heater having a fluid inlet manifold, a fluid outlet manifold, and a plurality of flow structures extending between the fluid inlet manifold and the fluid outlet manifold
Implementation Method 2
A pressure relief valve is arranged along the shunt flow path to block the flow of oil along the shunt flow path when the pressure differential between the first fluid port and the end of the shunt flow path is below a threshold, and to allow flow of oil along the shunt flow path when the pressure differential exceeds that threshold
Data Source
AI summary
A thermal management unit for a vehicle powertrain includes an integrated oil heater, a control valve, and a pressure relief valve. A remote oil cooler is connected to fluid ports of the thermal management unit. Transmission oil is received into the thermal management unit and is directed to one or both of the transmission oil heater and the transmission oil cooler. A portion of the flow of oil can be internally bypassed through the pressure relief valve to maintain the pressure of the oil below a threshold. The flow of oil is directed through the control valve after having been heated and/or cooled, and the proportions of oil being directed through the oil heater and the oil cooler are determined by the temperature of the oil in the control valve.