Thermal management module

A thermal management module comprises a housing and a drive shaft located within the housing. The housing is provided with a first internal cavity, a partition and a second internal cavity which are arranged in series along the axial direction of the drive shaft. The first internal cavity and the second internal cavity are separated by the partition. The partition is proved with a through-hole through which the drive shaft passes. One end of the drive shaft extends into the first internal cavity. A second internal cavity is used for receiving a drivetrain for rotating the drive shaft.

The present application claims the priority of Chinese patent application no. 201610479998.7 with invention title “Thermal management module”, submitted to the Chinese Patent Office on Jun. 27, 2016, the entire contents of which are incorporated herein by reference.

TECHNICAL FIELD

The present invention relates to the technical field of cooling systems, in particular to a thermal management module (abbreviated as TMM).

BACKGROUND

An engine cooling system on an existing motor vehicle is provided with a thermal management module mounted on the engine. The thermal management module can control the flow direction of coolant, so as to heat the engine when the engine temperature is low, and cool the engine when the engine temperature is high, so that the engine is kept operating at a suitable temperature at all times.

The thermal management module comprises a housing and a drive shaft located in the housing. The housing has a first internal cavity, a separating part and a second internal cavity arranged in sequence in the axial direction of the drive shaft. The first and second internal cavities are separated by the separating part. The separating part is provided with a through-hole for the drive shaft to pass through. One axial end of the drive shaft extends into the first internal cavity, so as to be connected to a valve body in the first internal cavity in a torsion-resistant manner; another axial end extends into the second internal cavity, so as to be connected to a drive apparatus in the second internal cavity. When the drive apparatus operates, it drives the drive shaft to rotate, and the drive shaft drives the valve body to rotate, to open a flow of coolant, cut off the flow of coolant, and control the flow direction of coolant.

The through-hole has first and second ports, wherein the first port faces toward the first internal cavity, the second port faces toward the second internal cavity, one axial end of the drive shaft extends into the first internal cavity from the first port, and the other axial end extends into the second internal cavity from the second port. The housing is provided with a leakage channel in communication with the atmosphere; an inlet of the leakage channel is disposed in a hole wall of the through-hole, and located between the first and second ports of the through-hole in the axial direction of the drive shaft. When coolant in the first internal cavity leaks out from the first port, the leaked coolant flows to the outside of the housing from the leakage channel, preventing the ingress of leaked coolant into the second internal cavity and consequent damage to the drive apparatus.

To prevent a user from seeing leaked coolant outside the housing, an existing thermal management module is additionally provided with a container, the container being disposed outside the housing and used for collecting leaked coolant. The container has a fixing support leg, which extends into the leakage channel of the housing and fits the leakage channel, to fix the container on the housing.

However, the existing thermal management module described above has the following shortcomings:

1. The container is disposed outside the housing, so the space occupied by the thermal management module is increased.

2. When the container is fixed to the housing, the fixing support leg of the container is easily broken, causing damage to the container.

3. The molding of the housing is already complex, and it is further necessary to provide a structure which fits the fixing support leg of the container, increasing the complexity of molding of the housing, and increasing the machining difficulty.

SUMMARY

The problems to be solved by the present invention are as follows: The container for collecting leaked coolant in the existing thermal management module is disposed outside the housing, so the space occupied by the thermal management module is increased. Furthermore, the container is easily damaged when being fixed to the housing, and the housing must be provided with a structure which fits the fixing support leg of the container, with the result that the complexity of molding of the housing is increased, and the machining difficulty is increased.

To solve the abovementioned problems, the present invention provides a thermal management module, comprising a housing and a drive shaft located in the housing, the housing having a first internal cavity, a separating part and a second internal cavity arranged in sequence in an axial direction of the drive shaft, the first and second internal cavities being separated by the separating part, the separating part being provided with a through-hole for the drive shaft to pass through, the through-hole having a first port facing toward the first internal cavity and a second port facing toward the second internal cavity, the drive shaft having one axial end extending from the first port into the first internal cavity, and another axial end extending from the second port into the second internal cavity, and the second internal cavity accommodating a drive apparatus for driving the drive shaft to rotate;

the housing is further provided with a collecting cavity, the collecting cavity having a collecting inlet provided in a hole wall of the through-hole, the collecting inlet being located between the first and second ports in the axial direction, and the collecting cavity being used for collecting, through the collecting inlet, coolant in the first internal cavity which leaks from the first port.

Optionally, the housing comprises first and second casings arranged in sequence in the axial direction, the first and second casings being in dismantlable fixed connection with each other;

the first internal cavity is disposed on the first casing, the second internal cavity is disposed on the second casing, the separating part comprises first and second end covers arranged opposite each other in the axial direction and enclosing the collecting cavity, the first end cover is located on the first casing, and located on one axial side of the first internal cavity, the second end cover is located on the second casing, and located on one axial side of the second internal cavity, the through-hole runs through the first and second end covers, the first port is disposed on the first end cover, and the second port is disposed on the second end cover.

Optionally, one of the first and second end covers is provided with a protruding boss on a surface facing the other end cover in the axial direction, the boss being in contact with the other end cover, so as to enclose the collecting cavity.

Optionally, there are two said bosses, spaced apart in the circumferential direction of the drive shaft.

Optionally, the boss is circularly arcuate.

Optionally, the collecting cavity has an outlet in communication with the atmosphere, the outlet allowing coolant in the collecting cavity to evaporate and be discharged.

Optionally, a seal is disposed at a position of contact between the first and second end covers, to prevent coolant in the collecting cavity from leaking from the position of contact.

Optionally, one of the first and second end covers is provided with a groove; a part of the seal is embedded in the groove, and another part protrudes from the groove, and forms a contact seal with the other end cover.

Optionally, the seal is a rubber member.

Optionally, the dismantlable fixed connection is a bolt connection.

Compared with the prior art, the technical solution of the present invention has the following advantages:

When coolant in the first internal cavity has leaked from the first port of the through-hole facing toward the first internal cavity, the coolant flows into the collecting cavity of the housing from the collecting inlet disposed in the hole wall of the through-hole and is stored in the collecting cavity. Hence, leaked coolant will not flow to the outside of the housing and be seen by a user, and will not flow into the second internal cavity from the second port of the through-hole facing toward the second internal cavity and damage the drive apparatus. Since the collecting cavity inside the housing has the function of collecting leaked coolant, there is no need for a special container for collecting leaked coolant to be provided outside the housing. In this way, not only is the space occupied by the thermal management module reduced, the problem of the container being easily damaged when being fixed to the housing is also avoided; furthermore, there is no need for the housing to be provided with a structure fitting a fixing support leg of a container, so the machining difficulty of the housing is reduced.

DETAILED DESCRIPTION

To enable the abovementioned object, features and advantages of the present invention to be more obvious and easier to understand, particular embodiments of the present invention are explained in detail below with reference to the accompanying drawings.

The present invention provides a thermal management module, capable of being used in various fields, so that an apparatus to be controlled is kept operating at a suitable temperature at all times. In this embodiment, the apparatus to be controlled is for example an engine on a motor vehicle, a gearbox, or a battery providing motive power for movement of a motor vehicle. In other embodiments, the apparatus to be controlled could also be used in technical fields other than the technical field of motor vehicles.

As shown inFIGS. 1 to 3, the thermal management module in this embodiment comprises a housing1and a drive shaft3located in the housing1. The housing1has a first internal cavity100, a separating part13and a second internal cavity113arranged in sequence in the axial direction of the drive shaft3. The first internal cavity100and second internal cavity113are separated by the separating part13. The separating part13is provided with a through-hole14for the drive shaft3to pass through. The through-hole14has a first port140facing toward the first internal cavity100, and a second port141facing toward the second internal cavity113. One axial end of the drive shaft3extends into the first internal cavity100from the first port140, so as to be connected to a valve body2in a torsion-resistant manner; another axial end of the drive shaft3extends into the second internal cavity113from the second port141, so as to be connected to a drive apparatus (not shown) in the second internal cavity113. When the drive apparatus operates, it drives the drive shaft3to rotate, and the valve body2can rotate under the driving action of the drive shaft3. When rotating, the valve body2is used to open a flow of coolant, cut off the flow of coolant, and control the flow direction of coolant.

The housing1is further provided with a collecting cavity12; the collecting cavity12has a collecting inlet121provided in a hole wall of the through-hole14, the collecting inlet121being located between the first port140and the second port141of the through-hole14in the axial direction of the drive shaft3. When coolant in the first internal cavity100has leaked from the first port140of the through-hole14, the coolant will not flow into the second internal cavity113from the second port141of the through-hole14, but will instead enter the collecting cavity12from the collecting inlet121, and be stored in the collecting cavity12. Hence, leaked coolant will not flow to the outside of the housing1and be seen by a user, and will not damage the drive apparatus as a result of flowing into the second internal cavity113. Since the collecting cavity12inside the housing1has the function of collecting leaked coolant, there is no need for a special container for collecting leaked coolant to be provided outside the housing1. In this way, not only is the space occupied by the thermal management module reduced, the problem of the container being easily damaged when being fixed to the housing is also avoided; furthermore, there is no need for the housing to be provided with a structure fitting a fixing support leg of a container, so the machining difficulty of the housing is reduced.

In this embodiment, the housing1comprises a first casing10and a second casing11which are arranged in sequence in the axial direction of the drive shaft3; the first casing10and second casing11are in dismantlable fixed connection with each other. In the technical solution of the present invention, the term “dismantlable fixed connection” means that the connection between the first casing10and the second casing11can be released without damaging the first casing10and the second casing11, to separate the first casing10and the second casing11.

In this embodiment, the dismantlable fixed connection is a bolt connection, i.e. the first casing10and the second casing11are connected together in a fixed manner by means of bolts7, such that the separation and fitting together of the first casing10and the second casing11is very convenient. Of course, in other embodiments, the dismantlable fixed connection between the first casing10and the second casing11could also be achieved in other ways, e.g. by a snap-fit connection.

The first internal cavity100is disposed on the first casing10, and the second internal cavity113is disposed on the second casing11. The separating part13comprises a first end cover102and a second end cover114, which are arranged opposite each other in the axial direction of the drive shaft3and enclose the collecting cavity12. The first end cover102is located on the first casing10, and located on one axial side of the first internal cavity100. The second end cover114is located on the second casing11, and located on one axial side of the second internal cavity113. The through-hole14runs through the first end cover102and the second end cover114. The first port140is disposed on the first end cover102, and the second port141is disposed on the second end cover114. The drive shaft3is rotatably supported on the first end cover102and the second end cover114.

In the technical solution of this embodiment, the first casing10and the second casing11may be machined separately, then fitted together so that the first end cover102and the second end cover114enclose the collecting cavity12, such that the machining of the housing1and the collecting cavity12is simpler. Of course, the housing1could also be integrally formed by precision machining.

In this embodiment, the first casing10further comprises a first hollow columnar part101, having an axial end in fixed connection with the first end cover102and enclosing the first internal cavity100. The second casing11further comprises a second hollow columnar part110, having one axial end in fixed connection with the second end cover114, and another axial end in fixed connection with a third end cover115. The second hollow columnar part110, the second end cover114and the third end cover115enclose the second internal cavity113.

As shown inFIG. 2, in this embodiment, a seal4is disposed at a position of contact between the first end cover102and the second end cover114, the seal4being capable of preventing coolant in the collecting cavity12from leaking from the position of contact. In this way, even if a minute gap exists at the position of contact between the first end cover102and the second end cover114due to machining error, the sealing action of the seal4can prevent coolant in the collecting cavity12from leaking from the gap to the outside of the housing1, reducing the possibility of coolant in the collecting cavity12leaking to the outside of the housing1.

In this embodiment, the seal4is a rubber member, which deforms under the squeezing action of the first end cover102and the second end cover114, and forms a contact seal with the first end cover102and the second end cover114. It must be explained that in the technical solution of the present invention, the structure of the seal4should not be restricted to the embodiment given.

In this embodiment, the second end cover114is provided with a groove111; a part of the seal4is embedded in the groove111, and another part protrudes from the groove111, and forms a contact seal with the first end cover102. When the thermal management module is assembled, the seal4is fixed on the second end cover114first, then the second casing11is connected to the first casing10in a fixed, dismantlable manner.

In a variation of this embodiment, the groove111is disposed on the first end cover102, and the seal4mounted in the groove111forms a contact seal with the second end cover114. When the thermal management module is assembled, the seal4is fixed on the first end cover102first, then the first casing10is connected to the second casing11in a fixed, dismantlable manner.

Compared with the second casing11, the molding of the first casing10is more complex; therefore, if the groove111is disposed on the first casing10, the machining difficulty of the first casing10will be increased, resulting in a higher rejection rate. To avoid this problem, the groove111is preferably disposed on the second casing11.

As shown inFIGS. 2 and 4, in this embodiment, a surface of the second end cover114which faces the first casing10in the axial direction of the drive shaft3is provided with a boss112protruding in the axial direction; the boss112is in contact with the first end cover102, so as to enclose the collecting cavity12.

In this embodiment, there are two bosses112, spaced apart in the circumferential direction of the drive shaft3; a gap between the two bosses112forms an outlet120in communication with the atmosphere, and there are two outlets120. In other words, the collecting cavity12is a non-closed cavity having outlets120. Coolant collected in the collecting cavity12can, after evaporating, be discharged from the outlets120; in this way, at the same time as the collecting cavity12collects leaked coolant, coolant in the collecting cavity12will be discharged to the outside of the housing1, so that even after the thermal management module has been used for a period of time, the collecting cavity12can still have surplus space to continue collecting leaked coolant, avoiding the problem of sustained collecting of leaked coolant being impossible due to insufficient space in the collecting cavity12.

In this embodiment, the groove111for mounting the seal4is disposed in one of the bosses112. When the thermal management module is mounted in an environment of use, the boss112in which the seal4is mounted is located below the other boss112in which no seal4is mounted, such that coolant in the collecting cavity12is in contact with the boss112in which the seal4is mounted, but is not in contact with the boss112in which no seal4is mounted. Since the seal4is mounted in the lower boss112, the sealing action of the seal4can prevent coolant from leaking from the position of contact between the lower boss112and the first casing10.

In a variation of this embodiment, both bosses112are provided with grooves111, and a seal4is mounted in each groove111, such that seals4are disposed at both positions where the two bosses112on the second casing11are in contact with the first casing10. In this way, when the thermal management module is mounted in an environment of use, the upper/lower relative positions of the two bosses112can be arranged arbitrarily.

In this embodiment, when viewed in the axial direction of the drive shaft3, the shape of the seal4is adapted to the shape of the boss112. Specifically, the seal4and the boss112are both circularly arcuate, the two bosses112are distributed on the same circumference, and the axial cross section of the collecting cavity12is circular. It must be explained that in the technical solution of the present invention, the shapes of the boss112, the seal4and the collecting cavity12should not be restricted to this embodiment; for example, viewed in the axial direction of the drive shaft3, the bosses112and the seal4could also be U-shaped, elliptically arcuate, etc.

In a variant of this embodiment, there may be a single boss112, formed in the shape of a ring having a gap, the gap forming an outlet120.

In another variant of this embodiment, a boss112is disposed on a surface of the first end cover102facing the second casing11in the axial direction of the drive shaft3; the boss112is in contact with the second casing11so as to enclose the collecting cavity12.

It must be explained that in the technical solution of the present invention, the way in which the first casing10and the second casing11enclose the collecting cavity12should not be restricted to the embodiment given; furthermore, the way in which the outlet120is constructed on the collecting cavity12, and the way in which the seal4is disposed at the position of contact between the first casing10and the second casing11, should also not be restricted to the embodiment given.

As shown inFIG. 2, in this embodiment, a first sealing ring5and a second sealing ring6spaced apart in the axial direction are provided around the drive shaft3, wherein the first sealing ring5is used to prevent coolant in the first internal cavity100from leaking between the first end cover102and the drive shaft3, and the second sealing ring6is used to prevent coolant from leaking between the second end cover114and the drive shaft3into the second internal cavity113. When coolant in the first internal cavity100leaks out from the first sealing ring5, the coolant is collected in the collecting cavity12directly.

In this embodiment, the drive apparatus in the second internal cavity113comprises an electric machine; an output end of the electric machine is connected to the axial end of the drive shaft3extending into the second internal cavity113, such that torque outputted by the electric machine can be transferred to the drive shaft3.

In a variation of this embodiment, the drive apparatus further comprises a gear speed reduction mechanism; the output end of the electric machine is connected to an input end of the gear speed reduction mechanism, and an output end of the gear speed reduction mechanism is connected to the axial end of the drive shaft3extending into the second internal cavity113. In this way, torque outputted by the electric machine is transferred to the drive shaft3via the gear speed reduction mechanism. It must be explained that in the technical solution of the present invention, the structure of the drive apparatus should not be restricted to the embodiment given.

Although the present invention has been disclosed as above, the present invention is not limited to this. Any person skilled in the art could make various changes and amendments within the spirit and scope of the present invention, therefore the scope of protection of the present invention shall be the scope defined in the claims.