Vehicle Thermal Management Module for Heat Exchange and Vibration Isolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electric vehicles face reduced mileage and battery performance due to heating systems and temperature challenges, requiring an integrated thermal management module that optimizes space, reduces vibration, and minimizes manufacturing costs.
Innovation Solution
An integrated thermal management module with a heat dissipation fan module and cooling medium circulating unit mounted on a cross member, using bushes to offset vibration and enhance heat exchange between external air and a cooling medium, ensuring efficient thermal management and space utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If electric vehicles use electricity-based heating systems instead of engine waste heat, then the heating function is achieved, but the vehicle mileage is significantly decreased
Solution Approach 1:
The patent combines the air conditioning system and heat management system into a single integrated thermal management module. The heat pump unit can operate in both heating and cooling modes, and the heat exchangers serve dual purposes for both cabin temperature control and battery thermal management, thereby reducing overall energy consumption and improving vehicle mileage while maintaining heating functionality.
Solution Approach 2:
The integrated thermal management module performs multiple functions: the heat pump unit provides both heating and cooling for the cabin, the first heat exchanger manages both cabin temperature and battery cooling, and the system can switch between different operating modes (heating mode, cooling mode, idle mode) to optimize energy usage across different scenarios.
2Adaptability or versatility
If battery modules operate in non-optimal temperature environments, then the battery can function in various external conditions, but the battery performance and lifespan are reduced
Solution Approach 1:
The patent integrates the battery thermal management system with the air conditioning system. The first heat exchanger serves dual purposes: it cools the cabin air during summer and cools the battery module when needed. The heat pump unit can redirect refrigerant flow to provide cooling to either the cabin or the battery, ensuring the battery operates in an optimal temperature range while maintaining the system's adaptability to various external conditions.
Solution Approach 2:
The first heat exchanger acts as an intermediary between the cabin air conditioning system and the battery thermal management system. It transfers heat between the refrigerant circuit and either the cabin air or the battery cooling fluid, enabling the battery to maintain optimal temperature while the system adapts to different external environmental conditions.
3Volume of moving object
If components are modularized and compact in an integrated thermal management module, then space utilization is improved, but the manufacturing complexity and coupling strength requirements increase
Solution Approach 1:
The integrated thermal management module is divided into distinct functional segments: the heat pump unit with compressor and expansion valve, the first heat exchanger with dual cooling channels, the second heat exchanger for battery cooling, and various valves and fluid circuits. This segmentation allows for modular assembly and simplified manufacturing while maintaining compact integration, reducing the overall volume compared to separate systems.
Solution Approach 2:
The patent merges multiple previously separate systems (air conditioning and battery thermal management) into a single integrated module with shared components. The first heat exchanger serves both cabin cooling and battery cooling functions, the refrigerant circuit is shared between heating and cooling modes, and the compressor serves both functions. This consolidation significantly reduces the total volume occupied while the modular design with clear functional segments keeps manufacturing complexity manageable.
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 effectively manages heat and vibration, maintaining battery performance, reducing vehicle mileage reduction, and maximizing internal space while minimizing manufacturing costs and vibration impact.
Implementation Method 1
a heat dissipation fan module configured to exchange heat of external air of the vehicle with heat of a cooling medium of an outdoor heat exchanger
Implementation Method 2
the integrated thermal management module being capable of offsetting the vibration generated from the heat dissipation fan module and the cooling medium circulating unit by using bushes
Data Source
AI summary
An embodiment integrated thermal management module of a vehicle includes a heat dissipation fan module disposed between opposite side frames of an underbody of the vehicle and mounted on a cross member that connects the opposite side frames to each other, the heat dissipation fan module being configured to transfer vibration to the cross member and to exchange heat of external air of the vehicle with heat of a cooling medium of an outdoor heat exchanger, and a cooling medium circulating unit provided on a side of the heat dissipation fan module.