Vehicle Thermal Module Mounting Layout for Space-Constrained PBVs
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Solution Overview
Problem
The challenge in mounting a thermal management module in a Purpose Built Vehicle (PBV) is the limited space available, which complicates the layout of pipes for coolant and refrigerant flow and reduces internal space, making it difficult to stably mount the module while minimizing the mounting space in front of the vehicle body.
Innovation Solution
A mounting structure comprising front side members, a dash reinforcement crossmember, and modular mounting brackets that divide the space into sections, allowing for the stable mounting of a thermal management module with a coolant circulator and refrigerant circulator, minimizing pipe usage and optimizing space utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the thermal management module is mounted on the upper vehicle body to overcome rolling chassis space limitations, then the mounting space problem is temporarily solved, but the internal space of the upper vehicle body is reduced
Solution Approach 1:
The patent transitions from vertical mounting on the upper vehicle body to horizontal mounting on the rolling chassis, utilizing the previously underutilized front space dimension. The mounting bracket extends in the width direction of the vehicle, transforming the mounting approach from occupying vertical interior space to utilizing horizontal exterior space, thereby resolving the conflict between mounting space availability and internal space preservation.
2Volume of moving object
If the constituent elements are disposed in a narrow mounting space on the rolling chassis, then the internal space is preserved, but the layout of pipes becomes complicated and mounting stability is compromised
Solution Approach 1:
The patent combines multiple constituent elements (coolant circulator, refrigerant circulator, and associated piping) into an integrated thermal management module. This merging allows the entire assembly to be mounted as a single unit on the rolling chassis, simplifying the pipe layout by eliminating the need for complex interconnections between separately disposed elements and reducing the overall mounting space required.
3Ease of manufacture
If the thermal management module is mounted using conventional methods, then mounting simplicity is maintained, but mounting stability and space optimization are compromised
Solution Approach 1:
The mounting system is segmented into distinct functional components: a mounting bracket with support portions for structural attachment, a coupling portion for module connection, and reinforcement crossmembers for structural stability. This segmentation allows each component to be optimized for its specific function while maintaining overall mounting simplicity through modular assembly, thereby achieving both ease of manufacture and mounting stability.
Data Source
AI summary
A mounting structure of a thermal management module for a vehicle according to an embodiment of the present disclosure includes: front side members extending along a length direction of a vehicle and disposed on left and right sides of the vehicle, respectively, in a width direction of the vehicle; a dash reinforcement crossmember extending along the width direction of the vehicle and coupled to rear ends of the front side members on the left and right sides based on a front and rear direction of the vehicle; a crossmember dividing a space formed by the front side members into two spaces in the front and rear direction of the vehicle; and at least one mounting bracket, on which the thermal management module is mounted, configured to mount the thermal management module in one of the two spaces divided by the crossmember.