Integrated Thermal Management Module for Compact EV Fluid Routing

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Solution Overview

Problem

In vehicles with electric drives, the reduced installation space and increased number of heat sources require a thermal management system that minimizes space and weight while simplifying manufacturing and enhancing reliability.

Innovation Solution

A modular thermal management module with integrated fluid handling elements, including distribution elements and auxiliary components, designed for maximum functional integration and reduced installation space, using plastic materials and a two-part auxiliary element design for acoustic decoupling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the number of fluid handling elements is increased to manage more heat sources in electric vehicles, then the thermal management capability is improved, but the installation space requirement increases exponentially

Engineering Contradiction:

Improvethermal management capabilityVSAvoidinstallation space

Core Design Contradiction:

Adaptability or versatilityVSVolume of stationary object

Solution Approach 1:

The patent combines multiple fluid handling elements (valves, pumps, sensors, heat exchangers) into a single integrated thermal management module. This consolidation reduces the number of separate components and their associated installation spaces while maintaining the ability to manage multiple heat sources through internal circuit configurations

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated module is designed to handle multiple thermal management functions simultaneously - cooling the battery, cooling the motor, heating the cabin, and managing thermal energy recovery. A single multi-functional module replaces what would traditionally require multiple separate components, thereby reducing installation space while maintaining versatility

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If the number of fluid handling elements is increased to connect various circuits, then the thermal management capability is improved, but the system weight increases due to more hoses

Engineering Contradiction:

Improvecircuit connectivityVSAvoidsystem weight

Core Design Contradiction:

Adaptability or versatilityVSWeight of stationary object

Solution Approach 1:

By integrating multiple fluid handling elements into a single compact module with internal fluid pathways, the patent eliminates the need for numerous external hoses and connections. The internal channels within the module replace what would otherwise require multiple external fluid conduits, thereby reducing system weight while maintaining circuit connectivity

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If numerous hoses and connections are used to connect fluid handling elements, then the thermal management coverage is improved, but the manufacturing process complexity increases

Engineering Contradiction:

Improvethermal management coverageVSAvoidmanufacturing process simplicity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent integrates multiple fluid handling elements (valves, pumps, sensors, heat exchangers) into a single pre-assembled module with internal fluid pathways. This consolidation reduces the number of separate components that need to be individually installed and connected, thereby simplifying the manufacturing and assembly process while maintaining comprehensive thermal management coverage

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The thermal management module is pre-assembled and pre-tested as a complete unit before installation in the vehicle. All internal connections and fluid pathways are established during module manufacturing rather than during vehicle assembly, which simplifies the overall manufacturing process and reduces assembly complexity

Inventive Principle:

Principle #10Preliminary action

4Adaptability or versatility

If numerous hoses and connections are used to connect fluid handling elements, then the thermal management coverage is improved, but the assembly time and cycle time increase

Engineering Contradiction:

Improvethermal management coverageVSAvoidassembly cycle time

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

By consolidating multiple fluid handling elements into a single integrated module with internal fluid pathways, the patent reduces the number of separate installation steps required. The module is installed as one unit rather than requiring the sequential installation and connection of multiple separate components, thereby significantly reducing assembly time and improving productivity

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentEP3746322B2Thermomanagementmodule for managing fluids, and method for the production thereof

Publication Date: 2026.01.21 WOCO INDUSTRIETECHNIK GMBH

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Figure 3~5
Figure 6a~6d

AI summary

The invention relates to a device (1) for managing at least one fluid within a vehicle, in particular an at least partially electrically driven vehicle, comprising at least one substantially planar first distribution element (3) and at least one second distribution element (5) arranged substantially parallel to the first distribution element (3), wherein the first distribution element (3) and/or the second distribution element (5) comprises or comprise at least in some regions at least one fluid management element (7, 9, 11, 13, 15, 17, 19, 21, 23, 25, 27, 29, 31, 33, 35, 37, 39, 41, 43, 45, 47, 49, 51), and wherein the first distribution element (3) and the second distribution element (5) comprise plastic at least in some regions. The invention also relates to a method for producing a device (1) for managing at least one fluid, in particular at least one device according to the invention.