Integrated Vehicle Thermal Module With Internal Refrigerant Flow Paths
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Solution Overview
Problem
Conventional thermal management modules in vehicles face issues with fluid leaks and inefficiencies due to external refrigerant pipes and hoses, which can lead to hazards with flammable refrigerants and reduced system efficiency.
Innovation Solution
A thermal management module with an integrated housing that encloses all components and forms internal refrigerant flow paths, eliminating external connections and minimizing leakage risks while optimizing refrigerant flow for improved efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external refrigerant pipes and hoses are used to connect components, then the system is easier to manufacture and assemble, but fluid leaks occur and system reliability deteriorates
Solution Approach 1:
The patent merges multiple separate components (compressor, condenser, expansion device, chiller) into a single integrated housing with internal flow paths. This consolidation eliminates external refrigerant pipes and hoses, preventing fluid leaks while maintaining system functionality. The housing acts as a unified structure that combines what were previously separate elements requiring external connections.
2Productivity
If external refrigerant pipes and hoses are used, then device assembly is easier, but refrigerant volume increases and energy efficiency deteriorates
Solution Approach 1:
The patent extracts and eliminates the external refrigerant pipes and hoses from the system, retaining only the essential internal flow paths within the integrated housing. This removal of unnecessary external connections reduces the total refrigerant volume required in the system and eliminates energy losses associated with external piping, thereby improving energy efficiency.
3Object-affected harmful factors
If external refrigerant pipes and hoses are used for component connections, then manufacturing and assembly are easier, but leakage risks increase and safety deteriorates
Solution Approach 1:
The patent combines multiple components into a single integrated housing with internal flow paths, eliminating the need for external refrigerant pipes and hoses. This merging approach prevents leakage at external connection points, thereby improving safety especially for vehicles using flammable refrigerants, while the integration is achieved through modular design that maintains manufacturing feasibility.
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 design enhances safety by preventing leaks and improves efficiency by reducing refrigerant volume and minimizing external interference, particularly suitable for vehicles using flammable refrigerants.
Implementation Method 1
a first flow path from a discharge of the compressor to an inlet of the condenser
Implementation Method 2
a third flow path from the chiller to a suction of the compressor
Data Source
AI summary
A thermal management module is provided. The thermal management module includes a housing that encloses a compressor, the housing fixedly retaining a condenser, an expansion device, and a chiller. The housing integrally forms a plurality of flowpaths within the housing that are configured for refrigerant to flow therethrough, including a first flow path from a discharge of the compressor to an inlet of the condenser, a second flow path from the expansion device to an inlet of the chiller, and a third flow path from the chiller to a suction of the compressor, wherein each of the first flow path, the second flow path, and the third flow path are each integrally formed within the housing.