Integrated Thermal Module Layout for Low-Pressure Vehicle Cooling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional thermal management modules face issues with mechanical strength, reliability due to plastic material failure, and complex fluid flow circuits leading to pressure drops and packaging challenges in vehicular environments.
Innovation Solution
A thermal management module design where a robust heat exchanger, capable of withstanding loads, acts as a structural component for mounting fluid pumps and heat exchangers, featuring a plastic fluid hub with multi-way valves and a distribution system that simplifies fluid flow circuits and reduces connectors, thereby enhancing mechanical strength and compactness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a plastic fluid hub is used to mount components, then packaging space is reduced, but mechanical strength and reliability deteriorate due to material failure
Solution Approach 1:
The patent merges the fluid hub structure with the heat exchanger by integrating the plastic fluid hub directly onto the heat exchanger body, eliminating the need for separate mounting brackets and reducing overall packaging space. This combination allows compact arrangement while distributing mechanical loads across both components.
Solution Approach 2:
The heat exchanger serves dual functions: thermal exchange and structural support for mounting the fluid hub and other components. This multi-functionality reduces the need for additional structural components, saving space while maintaining mechanical strength through proper design of the heat exchanger's mounting surfaces.
2Ease of manufacture
If plastic welding is used to join fluid hub components, then manufacturing is simplified, but reliability deteriorates due to welding failure
Solution Approach 1:
The patent introduces intermediary elements such as reinforcement ribs, mounting flanges, and separate mounting brackets that are either injection-molded as single pieces with the fluid hub or attached through more reliable methods. These intermediaries distribute stresses away from the plastic welding joints, preventing failure while maintaining ease of manufacture.
3Adaptability or versatility
If multiple connectors are used in fluid flow circuits, then component mounting is flexible, but pressure drop increases
Solution Approach 1:
The patent merges multiple fluid flow passages and connectors into an integrated plastic fluid hub with built-in channels and ports. This consolidation reduces the number of separate connectors and joints in the fluid circuit, minimizing pressure drops while maintaining flexible component mounting capabilities through the hub's multiple connection points.
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 solution provides a reliable and compact thermal management system that effectively manages fluid flow, reduces pressure drops, and addresses mechanical strength and packaging issues by strategically mounting components on a robust heat exchanger, ensuring efficient cooling and reduced vibration impact.
Implementation Method 1
The heat exchanger adapted to cool fluid received from the fluid pump for circulation through the heat generating components disposed in the vehicle
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A thermal management module 100 includes a fluid hub 10, at least one fluid pump 30a, 30b and at least one heat exchanger 20. The fluid hub 10 includes fluid flow passages and multi-valves for defining and regulating fluid supply to the heat exchanger 20 to configure selective fluid communication between the fluid hub 10 and the heat exchanger 20. The fluid pump 30a, 30b is for circulation of fluid through the fluid flow passages and the heat exchanger 20 and for configuring fluid flow therebetween. The heat exchanger 20 is adapted to cool fluid received from the fluid pump for circulation through the heat generating components of the vehicle. The heat exchanger 20 with the fluid pump 30a, 30b mounted thereon is mounted on a vehicle and at least a portion of the fluid hub 10 is supported between the fluid pump 30a, 30b and the heat exchanger 20.