COOLANT ROUTING SYSTEM WITH COUPLING DEVICE

Description

This nonprovisional application is a continuation of International Application No. PCT/US2023/24002, which was filed on May 31, 2023, which is herein incorporated by reference.

BACKGROUND OF THE INVENTION

Field of the Invention

A coolant routing system comprising a coolant tank of a coolant manifold assembly and a coupling device is described herein.

Description of the Background Art

Compared to vehicles with combustion engines, motor vehicles with electric drives have the disadvantage that they require more complex cooling systems. Whereas with a combustion engine only the engine heat has to be dissipated through a coolant circuit, which also requires only one coolant circuit in the event of additional use of the engine heat for heating the interior of the vehicle, electrically powered vehicles usually require different coolant circuits that are separate from each other. On the one hand, excess engine heat must be dissipated and, on the other hand, a vehicle battery and the vehicle interior must be either cooled or heated, depending on the ambient temperature of the vehicle, in order to ensure optimal functioning of the electrically powered motor vehicle. For instance, the vehicle battery must be heated in the case of low ambient temperatures, even if no excess engine heat needs to be dissipated, and cooled in case of substantial power output. Therefore, in addition to a cooling device for lowering a coolant temperature, also a heating device for raising to coolant temperature is required for electric drive vehicles.

An example of feeding and controlling multiple coolant circuits for an electric vehicle is disclosed by document WO 2017/223 232 A2, which corresponds to US 2017/0373359. This document discloses a coolant tank for an electric drive vehicle, which has several components arranged inside it for implementing multiple coolant circuits. The positioning of the components, for example the tubes for the multiple coolant circuits, inside the tank is space-efficient. However, in case of damage or necessary maintenance of these components, they are difficult to access. Furthermore, the relocation of device components inside the coolant tank creates thermal bridges between components of the different coolant circuits. This increases a control effort for the multiple coolant circuits. Moreover, the capacity of the coolant tank is reduced by each device component moved to the inside of the tank, so that the tank must be enlarged to provide a certain coolant capacity. In addition, a tank with internal components is significantly more difficult to manufacture than a tank that is merely configured to receive and store coolant.

SUMMARY OF THE INVENTION

It is therefore an object of the present invention to provide a coolant routing system for a vehicle having several coolant circuits that overcomes the above-discussed disadvantages.

In an example, a coolant routing system is provided for a vehicle having a plurality of coolant circuits, for instance an electric drive vehicle, has a coolant tank, which is configured to store a coolant, and a coolant manifold assembly having a plurality of coolant tubes. The coolant tubes are each configured to form a part of one of the coolant circuits. Further, the coolant routing system has at least one coolant pump, which is configured to pump the coolant into at least one coolant circuit, and a coupling device, which is configured to introduce the coolant from the coolant tank into the coolant circuits. The coupling device is formed at least in part by a wall of the coolant tank and is coupled to both the at least one coolant pump and the coolant manifold assembly so that coolant can be exchanged between an interior of the coupling device and the at least one coolant pump and between the interior of the coupling device and the coolant manifold assembly.

Advantages of this arrangement are that the coolant routing system can feed several coolant circuits on the one hand, but at the same time is very space-efficient to implement and easy to install in a vehicle. The coolant tubes are easily accessible from the outside and thus can be easily checked for damage and serviced. The coupling device, which is partially formed by a wall of the coolant tank, is also easily accessible from the outside and can be easily checked and/or serviced for damage. In the event of damage to the coupling device or the coolant tubes or the coolant pump, these components can be easily replaced.

The coupling device can be at least partially formed by a planar outer wall of the coolant tank. This simplifies the construction as well as the assembly of the coolant routing system. It also makes it easier to replace a possibly damaged part of the coupling device that is not formed by the wall of the coolant tank. Optionally, both the coolant tank and the coupling device can be made of a plastic material.

The coolant tank can be formed by two tank components, which are coupled to each other. For example, the two tank components can each be half-shell-shaped or half-tank-shaped parts of a coolant tank produced by an injection molding process, in particular by a plastic injection molding process. Optionally, one tank component of the coolant tank and the coupling device may be formed integrally with each other.

The coupling device may comprise a plurality of coolant channels. Optionally, each of the plurality of coolant channels can be formed at least partially by a wall of the coolant tank. Coolant channels are not hoses, but rigid or inelastic coolant guides. Coolant channels facilitate the passage and guiding of coolant. Structures partially forming the coolant channels may be manufactured integrally with the coupling device, for instance by an injection molding process. The coupling device and the structures partially forming the coolant channels may comprise a manufacturing material similar to a manufacturing material of the coupling device and the coolant tank, for instance a plastic material.

Further, the coolant tank may be implemented such that the interior of the coolant tank is free of valves, pumps or coolant flow control devices. In other words, the coolant tank may be free of device components that are completely or partially located in the interior of the coolant tank.

An advantage of this is that the volume available for coolant in the interior of the coolant tank is maximized. Further, the temperature of the individual device components is not influenced by the temperature of the coolant in the coolant tank.

Further, the coupling device may also be implemented such that the interior of the coupling device is free of valves, pumps or control devices for a coolant flow. In other words, the coupling device can be free of device components which are completely or partially arranged in the interior space of the coupling device.

The coolant routing system may comprise a control valve, which is configured to control the introduction of coolant into at least a first coolant circuit. The control valve may comprise a rotary actuator. An advantage of the control valve is that the coolant from the coolant tank can be selectively feed to one or more of the coolant circuits.

The control valve may be arranged on the coupling device, in particular on the coolant channels. The coupling device may have one or more receiving sections for receiving or arranging control valves, for example control valves in the form of rotary actuators.

The control valve can be further configured to control the introduction of coolant into at least two coolant circuits.

The control valve may comprise at least two valve sections, each of which is configured to control the introduction of coolant into a respective one of the coolant circuits. The two valve sections may each be configured to be moved or rotated together.

For example, the control valve can be a rotatable fluid valve having at least two valve sections arranged along a common axis of rotation, each arranged to control and/or regulate different coolant circuits. The valve sections can be fixed to each other and arranged immovably with respect to each other, so that the valve sections can only be rotated together about the axis of rotation.

A control valve, which is configured to control or regulate at least two coolant circuits, can be arranged at least partially in or on two different coolant channels, wherein these at least two different coolant channels are each configured to introduce coolant into two different coolant circuits. The two different coolant channels can run and/or be arranged parallel to one another at least in sections in the region of the control valve. In one variant, the control valve can cross or at least partially penetrate at least one of the two mutually different coolant channels.

An advantage here is that two coolant circuits can be controlled by a single valve, so that the effort required to control or move the valves is reduced. Furthermore, this improves the precision of the control of the coolant circuits, as a control valve with at least two valve sections that are immovable in relation to each other always defines a predetermined ratio between the coolant feeds into the different coolant circuits.

Further advantages of the control valve with a plurality of valve sections are an improvement in the space efficiency of the control valves compared to individual control valves for each coolant circuit and a reduction in the control or regulation effort.

The coolant routing system may further comprise a second control valve. The second control valve can be configured to control the introduction of coolant into a second coolant circuit.

The second control valve can comprise a rotary actuator.

The coolant manifold assembly can be releasably coupled to the coupling device. This facilitates a replacement or maintenance of a possibly damaged coolant manifold assembly.

Further, the coolant manifold assembly can comprise a hose connection for a coolant hose. This facilitates a connection of the coolant routing system to the coolant circuits of a vehicle. For example, the coolant manifold assembly can have at least 2, 4, 6, 8 or 10 coolant tubes comprising a hose connection.

The coolant routing system may comprise a coolant pump, which is configured to pump coolant into at least one of the coolant circuits. The coolant pump can be arranged on the coolant tank, on the coolant manifold assembly or on the coupling device.

The routing system may further comprise at least one temperature sensor configured to detect a temperature of a coolant in at least one of the coolant tubes.

Further, the coolant routing system can comprise a control or regulation for the one or more control valves and/or the at least one coolant pump, for example in the form of an electronic control or regulation device. The control or regulation device may be arranged on the coolant tank, on the coolant manifold assembly or on the coupling device. The coolant tank, the coolant manifold assembly or coupling device may further comprise one or more sockets for one or more control or regulation devices. Optionally, the control or regulation device may control the one or more control valves and/or the at least one coolant pump based on a detection of the temperature sensor.

Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes, combinations, and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus, are not limitive of the present invention, and wherein:

FIG. 1 shows an example of a coolant routing system from a first perspective.

FIG. 2 shows an example of a coolant routing system from a second perspective.

FIG. 3 shows an example of a coolant routing system from a third perspective.

FIG. 4 shows an example of a coolant routing system from a fourth perspective.

DETAILED DESCRIPTION

FIG. 1 shows a coolant routing system comprising a coolant tank 10 and a coupling device 20, which is releasably coupled to the coolant tank 10. In the coupled state, a bottom wall 15 of the coolant tank 10 forms a cover panel of the coupling device 20. In an alternative embodiment, the coupling device can be integrally formed with a component of the coolant tank.

The coolant tank 10 is adapted to store a coolant. Further, the coolant tank 10 is adapted to introduce coolant into the coupling device 20 and to receive coolant from the coupling device 20, respectively. Both the interior of coolant tank 10 and the interior of the coupling device 20 are free of hoses, pipes and other devices such as pumps or valves.

Further, FIG. 1 shows a manifold assembly 30 and the coolant pumps 40 and 50. Both the manifold assembly 30 and the coolant pumps 40, 50 are coupled to the coupling device 20 so that coolant can be exchanged between the interior of the coupling device 20 and the coolant pumps 40, 50 and between the interior of the coupling device 20 and the coolant manifold assembly 30. Both the manifold assembly 30 and the coolant pumps 40, 50 may form parts of coolant circuits that are to be feed with coolant from the coolant tank 10.

The coupling device 20 serves as a distribution hub for the coolant stored in the coolant tank 10. For guiding coolant from and to the manifold assembly 30 and the coolant pumps 40, 50, the coupling device 20 comprises a plurality of coolant channels 25. The coolant channels 25 are each formed by both the bottom wall of the coolant tank 10 and structures that are integrally formed with the coupling device 20. The coolant channels 25 form a guiding structure for coolant which is to be guided from or to the manifold assembly 30 or guided from or to the coolant pumps 40, 50.

The manifold assembly 30 and the coolant pumps 40, 50 are releasably coupled to the coupling device 20 that comprises the coolant channels 25. In the event of damage, the manifold assembly 30 and/or coolant pumps 40, 50 may be modularly replaced.

The coolant pumps 40, 50 are configured to pump the coolant from the coolant tank 10 to coolant circuits coupled to the coolant routing system. The coolant pumps 40, 50 are arranged on the coolant channels 25.

The manifold assembly 30 comprises a plurality of coolant tubes 35. The coolant tubes 35 are each configured to form a part of one of the coolant circuits, in particular of coolant circuits of an electric drive vehicle. A plurality of the coolant tubes 35 is arranged on the coolant channels 25 so that coolant can be exchanged between the interior of the coupling device 20 and the manifold assembly 30.

As shown in FIG. 1, at least some of the coolant tubes 35 comprise hose connections for coolant hoses. The hose connections can serve for coupling the coolant routing system to coolant circuits of a vehicle, in particular to coolant circuits of an electric drive vehicle.

FIG. 1 illustrates the interior of the coolant tank 10 and a coupling device 20. However, as can be seen from FIGS. 2 and 3, the interiors of the coolant tank 10 and the coupling device 20, which are configured to store and distribute the coolant, are of course surrounded by the walls of the coolant tank 10 and a coupling device 20, respectively.

FIG. 4 shows the interior of a coupling device 20 from another perspective than FIG. 1. For the sake of illustrating the interior of the coupling device 20, FIG. 4 does not show the coolant tank 10, which constitutes a cover or upper wall of the coupling device 20 when coupled to the coupling device 20.

FIG. 4 shows that the coupling device 20 comprises structures that form the coolant channels together with a bottom wall of the coolant tank when the coupling device 20 is coupled to the coolant tank 10. The coolant tubes 35 of the manifold assembly 30 are arranged on the coolant channels 25 so that coolant from the coolant tank can pass through the coupling device 20 into the coolant tubes 35. Further, also the coolant pumps 40, 50 are arranged on the coolant channels 25.

For regulating a flow of the coolant through the coolant routing system and/or through a coolant circuit coupled to the coolant routing system, the coolant routing system shown in the figures can be coupled to one or more control valves, which are configured to regulate a flow of the coolant through the coolant routing system and/or through one or more coolant circuits. The coolant pumps 40, 50 and/or the one or more control valves can be controlled or regulated by a control unit, which is configured to control or regulate the coolant pumps 40, 50 and/or at least one control valves.

The variants described above are merely intended to provide a better understanding of the structure, operation and properties of the objects disclosed herein; they do not limit the disclosure to the examples of embodiments. The Figs. are schematic, with essential features and effects shown, in some cases significantly enlarged, to illustrate the functions, operating principles, technical embodiments and features. In this context, any mode of operation, principle, technical embodiment and feature disclosed in the Fig. or in the text may be freely and arbitrarily combined with any claim, feature in the text and in the other Figs, other modes of operation, principles, technical embodiments and features contained in or resulting from this disclosure, so that all conceivable combinations are attributable to the described approach. Combinations between all individual embodiments in the text, i.e. in each section of the description, in the claims and also combinations between different variants in the text, in the claims and in the Figs. are also included. The claims also do not limit the disclosure and thus the possible combinations of all disclosed features with each other. All disclosed features are also explicitly disclosed here individually and in combination with all other features.

The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are to be included within the scope of the following claims.