Integrated Thermal Module With Internal Flow Channels for Vehicle Packaging
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Solution Overview
Problem
Existing vehicle thermal management systems have complex pipeline arrangements, high space occupation, difficult maintenance, and assembly challenges, which hinder efficiency and cost-effectiveness.
Innovation Solution
An integrated module for a vehicle thermal management system is introduced, featuring a body with flow channels and interfaces that connect thermal management devices directly, reducing the number of pipelines and integrating a valve set for simplified maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thermal management devices are connected through pipelines with scattered valves, then the system can be assembled, but the pipeline arrangement becomes complex and space occupation increases
Solution Approach 1:
The patent integrates multiple thermal management components (evaporator, condenser, expansion valve, etc.) into a single integrated module with internal flow channels. This merging eliminates the need for external pipelines and scattered valves, directly resolving the contradiction by reducing pipeline arrangement complexity while maintaining assembly ease through the pre-integrated structure.
Solution Approach 2:
The patent transitions from a one-dimensional pipeline connection system to a three-dimensional integrated module with internal flow channels. By embedding the flow channels within the module body, the system eliminates external pipeline complexity while maintaining functional connectivity, thus resolving the contradiction between assembly ease and pipeline arrangement complexity.
2Ease of manufacture
If thermal management devices are connected through pipelines, then the system can be assembled, but space occupation becomes high
Solution Approach 1:
The patent combines multiple thermal management components into a single integrated module, eliminating the need for external pipelines and reducing the overall space required for component arrangement. This directly addresses the contradiction by reducing space occupation while maintaining assembly ease through the integrated design.
Solution Approach 2:
The patent embeds flow channels within the body of the integrated module, nesting the fluid transport pathways inside the component structure itself. This eliminates the need for external pipelines and reduces space occupation, while the modular design maintains assembly ease.
3Ease of manufacture
If valves are scattered on pipelines, then the system can be assembled, but maintenance becomes difficult
Solution Approach 1:
The patent integrates all valves and thermal management components into a single modular unit. This merging allows the entire assembly to be treated as one replaceable component, dramatically improving maintenance ease by eliminating the need to access scattered valves on pipelines, while the modular design maintains assembly ease.
4Ease of manufacture
If pipelines are used to connect thermal management devices, then the system can be assembled, but assembly time becomes long
Solution Approach 1:
The patent integrates multiple thermal management components into a single pre-assembled module with internal flow channels. This eliminates the need for on-site pipeline installation and connection, directly reducing assembly time while maintaining assembly ease through the modular design that requires only single-point installation.
Solution Approach 2:
The patent performs the complex assembly of multiple components and internal flow channels in advance during manufacturing, creating a pre-integrated module. This preliminary action eliminates the need for time-consuming on-site pipeline installation and connection, directly reducing assembly time while maintaining ease of installation through the finished modular unit.
5Ease of manufacture
If multiple components are used in the thermal management system, then the system can be assembled, but the arrangement space of the entire vehicle increases
Solution Approach 1:
The patent combines multiple thermal management components (evaporator, condenser, expansion valve, etc.) into a single integrated module, dramatically reducing the arrangement space required in the vehicle. This merging directly addresses the contradiction by reducing arrangement space while maintaining assembly ease through the modular design that simplifies installation.
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 integrated module simplifies the thermal management system, reduces space and weight, lowers costs and assembly complexity, and enhances energy utilization by facilitating heat exchange between the air conditioning system and the battery or engine.
Implementation Method 1
at least one flow channel is provided in the body... configured to connect to corresponding thermal management devices in a thermal management system
Implementation Method 2
The first expansion valve is arranged on the flow channel between the second interface and the battery heat exchanger first opening interface, to cause the first expansion valve to throttle and depressurize a refrigerant from the second interface
Implementation Method 3
A battery heat exchanger is configured to exchange heat with a battery coolant circuit in which a battery is located, and the battery coolant circuit is configured to exchange heat with an engine coolant circuit in which an engine is located
Data Source
AI summary
An integrated module for a vehicle thermal management system comprises a body, a plurality of interfaces, and a valve set. The plurality of interfaces are provided on the body to be communicated with corresponding flow channels in the body; an indoor condenser outlet interface is connected to a first interface by means of the flow channel, a second interface is connected to a battery heat exchanger first opening interface by means of the flow channel, and a battery heat exchanger second opening interface is connected to a compressor inlet interface by means of the flow channel; a battery heat exchanger is configured to exchange heat with battery coolant circuits in which a battery and an engine are located; the valve set is provided on the body and comprises a first expansion valve provided on the flow channel between the second interface and the battery heat exchanger first opening interface.