Thermal Management Module With Dual Flanges for Compact Valve Layout
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Solution Overview
Problem
The existing thermal management modules in electric vehicles face challenges in space constraints due to the need for wide flanges to accommodate valve assemblies between heat exchangers, limiting installation space and fluid line separation for efficient refrigerant flow.
Innovation Solution
The introduction of a second flange on either the first or second heat exchanger allows for placement of valve assemblies on both flanges, reducing the width requirement of the first flange and enabling easier installation and connection of components, with fluid lines separated for different refrigerants, using expansion and unidirectional valves for controlled fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If valve assemblies are placed on a flange between two heat exchangers, then fluid flow control is achieved, but the flange width must be increased to accommodate the valve assemblies and their channels
Solution Approach 1:
The patent introduces a second flange on either the first or second heat exchanger, creating a second spatial dimension for valve assembly placement. This allows valve assemblies to be distributed across two separate flanges rather than crowded onto a single wide flange, thereby reducing the width requirement of each individual flange while maintaining fluid flow control functionality.
2Ease of operation
If the flange width is increased to accommodate valve assemblies, then valve placement is enabled, but the available installation space is reduced
Solution Approach 1:
The patent segments the valve assembly placement by providing two separate flanges instead of one consolidated wide flange. This segmentation allows valve assemblies to be distributed across different locations, reducing the concentrated space requirement and improving overall installation space utilization in the thermal management module.
3Ease of operation
If fluid lines for different refrigerants are separated, then p/T sensor placement is facilitated, but system complexity increases
Solution Approach 1:
The patent uses the second flange to create spatial separation of fluid lines for different refrigerants (e.g., chiller and evaporator lines). This spatial separation in another dimension allows p/T sensors to be easily placed in distinct locations without requiring complex routing arrangements, thereby facilitating sensor placement while avoiding excessive system complexity.
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 design optimizes installation space, allows for efficient fluid supply to heat exchangers, and facilitates easier placement and connection of components, enhancing thermal management in electric vehicles by reducing the need for extensive flange width and improving refrigerant flow control.
Implementation Method 1
the first valve assembly is or contains an expansion valve. This expansion valve reduces the pressure in the fluid, e.g. a refrigerant, by restricting the flow cross section, thus allowing an increase in volume, or an expansion
Implementation Method 2
the second valve assembly is or contains a unidirectional valve. This type of unidirectional valve can be placed between the first heat exchanger and the evaporator, thus on the second flange, such that a refrigerant can flow at a regulated pressure from the evaporator to the first heat exchanger through the unidirectional valve. It cannot flow in the other direction.
Implementation Method 3
a first heat exchanger (2) and a second heat exchanger (3)... in which there are fluid channels (5) connecting the first heat exchanger (2) to the second heat exchanger (3) for fluid exchange
Data Source
AI summary
A thermal management module is provided. The module includesa first heat exchanger,a second heat exchanger,a first flange located between the first heat exchanger and second heat exchanger, in which there are fluid channels connecting the first heat exchanger to the second heat exchanger for fluid exchange, and a first receiver for a first valve assembly,a second flange on the first heat exchanger or second heat exchanger, which has a second receiver for a second valve assembly. This results in a compact structure and a means of supplying fluid to the first heat exchanger and second heat exchanger from different directions.