An integrated heat exchanger module for an automotive thermal management system

Abstract

The present invention discloses an integrated heat exchanger module of an automobile thermal management system, comprising a high-temperature heat exchange zone, a medium-temperature heat exchange zone and a low-temperature heat exchange zone stacked in sequence, a top plate installed on one side of the low-temperature heat exchange zone, and an expansion valve assembly installed on the top plate, the high-temperature heat exchange zone, the medium-temperature heat exchange zone and the low-temperature heat exchange zone are all composed of stacked plates, and adjacent plates form alternating and independent first heat exchange channels and second heat exchange channels, wherein the high-temperature heat exchange zone is equivalent to a water-cooled condenser, the medium-temperature heat exchange zone is equivalent to an intermediate heat exchanger, and the low-temperature heat exchange zone is equivalent to a battery cooler; no external pipeline is required for connection, which greatly reduces the production and testing costs of parts and components, and greatly reduces the vehicle-end mounting bracket, connecting pipes, bolts and labor costs.

Description

Technical Field

[0001] The present invention relates to the technical field of automobile thermal management systems, and in particular to an integrated heat exchanger module of an automobile thermal management system. Background Art

[0002] Electric vehicle thermal management systems impact vehicle safety, range, energy consumption, and comfort, and have become a core technology for new energy vehicles. With the development of new technologies like wide-temperature heat pumps and R290 (propane) systems, water-source heat pump systems for new energy vehicles are gaining industry recognition due to their high efficiency. Existing water-source architecture systems include at least two plate heat exchangers: a water-cooled condenser and a chiller (battery cooler). The R290 system also incorporates an intermediate heat exchanger (IHX) to improve system heat transfer efficiency. Because each heat exchanger contains refrigerant and coolant channels, and the water-cooled condenser uses high-temperature, high-pressure refrigerant, while the chiller uses low-temperature, low-pressure refrigerant, all current heat exchangers are independent, connected by air conditioning and water pipes, or by their own refrigerant or water channels. As a result, the three heat exchangers in the system need to be independently produced, assembled, welded, and tested at the supplier's site; and they need to be assembled and tested separately on the vehicle system or module. In addition, connecting the three independent parts requires pipes and corresponding bolt brackets, which increases the cost of parts. In addition, the longer pipes increase the amount of refrigerant to be filled. Due to the flammable and explosive nature of R290 (propane), the smaller the filling amount, the safer it is. Therefore, a heat exchanger module that can integrate the three heat exchangers is needed to solve the above problems. Summary of the Invention

[0003] The present invention provides an integrated heat exchanger module for an automobile thermal management system, which can solve the problem of complex installation structure and piping structure caused by the need for three independent heat exchangers in the existing automobile thermal management system.

[0004] To achieve the above-mentioned objectives, the present invention provides the following technical solutions: an integrated heat exchanger module for an automotive thermal management system, comprising a high-temperature heat exchange zone, a medium-temperature heat exchange zone, and a low-temperature heat exchange zone stacked in sequence, a top plate installed on one side of the low-temperature heat exchange zone, an expansion valve assembly installed on the top plate, the high-temperature heat exchange zone, the medium-temperature heat exchange zone, and the low-temperature heat exchange zone all being composed of stacked plates, and mutually alternating and independent first heat exchange channels and second heat exchange channels are formed between adjacent plates, wherein the high-temperature heat exchange zone is equivalent to a water-cooled condenser, the medium-temperature heat exchange zone is equivalent to an intermediate heat exchanger, and the low-temperature heat exchange zone is equivalent to a battery cooler, different media flow in the first heat exchange channel and the second heat exchange channel, heat exchange is performed between the different media, and the flow directions of the media in the first heat exchange channel and the second heat exchange channel are opposite;

[0005] The first heat exchange channel in the high-temperature heat exchange area is connected to the low-temperature cooling water inlet channel and the high-temperature cooling water outlet channel, and the second heat exchange channel in the high-temperature heat exchange area is connected to the high-temperature refrigerant inlet channel and the high-temperature refrigerant outlet channel. The high-temperature refrigerant inlet channel is used to connect the high-temperature refrigerant from the compressor. Low-temperature cooling water circulates in the first heat exchange channel to perform heat exchange with the high-temperature refrigerant, thereby reducing the temperature of the high-temperature refrigerant.

[0006] The first heat exchange channel in the medium-temperature heat exchange zone is connected to the first medium-temperature heat exchange channels located on both sides of the medium-temperature heat exchange zone, and the second heat exchange channel in the medium-temperature heat exchange zone is connected to the second medium-temperature heat exchange channels located on both sides of the medium-temperature heat exchange zone, which can further reduce the temperature of the high-temperature refrigerant while increasing the temperature of the low-temperature refrigerant returning from the low-temperature heat exchange zone;

[0007] The first heat exchange channel in the low-temperature heat exchange zone is connected to the cooling water inlet channel and the cooling water outlet channel, the second heat exchange channel in the low-temperature heat exchange zone is connected to the first transition channel and the second transition channel, the first transition channel is connected to the outlet of the expansion valve assembly, the second transition channel is connected to one of the second medium-temperature heat exchange channels, and the other second medium-temperature heat exchange channel is connected to the low-temperature refrigerant outlet channel in the high-temperature heat exchange zone. In the low-temperature heat exchange zone, the low-temperature and low-pressure refrigerant after the pressure is reduced by the expansion valve assembly is exchanged with the cooling water entering from the cooling water inlet channel, absorbs the heat of the cooling water, and completely evaporates into a low-temperature and low-pressure gaseous refrigerant;

[0008] One of the first medium-temperature heat exchange channels is connected to the high-temperature refrigerant outlet channel, and the other first medium-temperature heat exchange channel is connected to the first straight through channel in the low-temperature heat exchange zone, and the first straight through channel is connected to the inlet of the expansion valve assembly;

[0009] By designing the internal channels of the high-temperature heat exchange zone, the medium-temperature heat exchange zone and the low-temperature heat exchange zone, the three are integrated together without the need for external pipes for connection, which reduces the amount of refrigerant to be added and solves the problem of complex installation structure and piping structure caused by the existing need for three independent heat exchangers.

[0010] Preferably, a first partition is provided between the high-temperature heat exchange zone and the medium-temperature heat exchange zone, and a second partition is provided between the medium-temperature heat exchange zone and the low-temperature heat exchange zone. By providing the first partition and the second partition, the three heat exchange zones can be separated, and the corresponding channels that need to be isolated can also be isolated.

[0011] Preferably, fins are installed in the first heat exchange channel and the second heat exchange channel to improve the heat exchange efficiency.

[0012] Preferably, the expansion valve assembly includes a pressure block mounted on the top plate and an expansion valve mounted at one end of the pressure block. The first straight-through channel and the first transition channel are respectively connected to the inner sides of both ends of the pressure block. The expansion valve is integrated into the heat exchanger through the pressure block, and the pressure block can also serve as a valve seat to restrict the inlet and outlet, thereby facilitating docking with the first straight-through channel and the first transition channel.

[0013] Preferably, the low-temperature cooling water inlet channel and the high-temperature cooling water outlet channel are located at a pair of diagonally opposite corners of the high-temperature heat exchange zone, and the high-temperature refrigerant inlet channel and the high-temperature refrigerant outlet channel are located at another pair of diagonally opposite corners of the high-temperature heat exchange zone, which can effectively utilize the space of the high-temperature heat exchange zone to increase the efficiency of heat exchange.

[0014] Preferably, the first transition channel and the second transition channel are arranged side by side on one side of the low-temperature heat exchange zone, and the cooling water inlet channel and the cooling water outlet channel are arranged side by side on the other side of the low-temperature heat exchange zone, and the plates in the low-temperature heat exchange zone include first and second low-temperature heat exchange plates that are staggered and stacked, wherein a first separating rib is provided on the first low-temperature heat exchange plate at a position between the first transition channel and the second transition channel, and a second separating rib is provided on the second low-temperature heat exchange plate at a position between the cooling water inlet channel and the cooling water outlet channel, which cooperates with the first separating rib, and the first separating rib is embedded in the groove in the middle of the second separating rib. By arranging the first separating rib and the second separating rib, U-shaped and opposite flow channels can be formed on the first heat exchange channel and the second heat exchange channel in the low-temperature heat exchange zone, respectively, which can improve the heat exchange efficiency between the cooling water and the low-temperature and low-pressure refrigerant, and at the same time, the first transition channel and the second transition channel can be concentratedly arranged near the expansion valve to facilitate the formation of a loop.

[0015] Preferably, a base plate is installed on the side of the high-temperature heat exchange zone, a mounting plate is connected to the outer side of the base plate, and an agent side joint connected to the high-temperature refrigerant inlet channel and the low-temperature refrigerant outlet channel is installed on the mounting plate. By setting the mounting plate, it is convenient to directly connect the integrated heat exchanger module with the compressor, and the agent side joint is convenient for docking with the refrigerant inlet and outlet of the compressor.

[0016] Preferably, a joint pipe connected to the cooling water inlet channel and the cooling water outlet channel is installed on the top plate, and the top plate is conducive to sealing the low-temperature heat exchange area.

[0017] Preferably, the edges of the plates, the first partition and the second partition are all provided with protruding marking portions, and the positions of the marking portions on the high-temperature heat exchange zone, the medium-temperature heat exchange zone, the low-temperature heat exchange zone, the first partition and the second partition are all different. By setting marking portions in different positions, the high-temperature heat exchange zone, the medium-temperature heat exchange zone, the low-temperature heat exchange zone, the first partition and the second partition can be quickly distinguished, which is convenient for installation and will not cause the problem of incorrect installation.

[0018] Preferably, the plates, the first partition, the second partition, the bottom plate and the top plate are connected by brazing, and the assembly is firm and reliable.

[0019] Compared with the prior art, the present invention has the following beneficial effects:

[0020] By designing the internal channels of the high-temperature heat exchange zone, the medium-temperature heat exchange zone and the low-temperature heat exchange zone, the three are integrated together. At the same time, the expansion valve is integrated into the heat exchanger to form a three-in-one heat exchanger integrated module. No external pipeline is required for connection, which greatly reduces the cost of component production and testing, and greatly reduces the cost of vehicle-end mounting brackets, connecting pipes, bolts and labor hours, reduces the amount of refrigerant to be added, has smaller flow resistance and higher efficiency, and solves the problem of complex installation structure and piping structure caused by the existing need for three independent heat exchangers. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 It is a three-dimensional structural diagram of the present invention;

[0022] Figure 2 It is a schematic diagram of the end structure of the present invention;

[0023] Figure 3 for Figure 2 AA cross-sectional structural diagram;

[0024] Figure 4 It is a three-dimensional structural diagram of the module decomposition of the present invention;

[0025] Figure 5 Schematic diagram of the refrigerant circulation circuit of the present invention;

[0026] Figure 6 This is a schematic diagram of the cooling water circulation circuit of the present invention;

[0027] Figure 7 This is a three-dimensional structural diagram of the first low-temperature heat exchange plate of the present invention;

[0028] Figure 8 This is a three-dimensional structural diagram of the second low-temperature heat exchange plate of the present invention;

[0029] Figure 9 It is the overall circuit principle diagram of the present invention.

[0030] Reference numerals:

[0031] 1. Plate, 11. Fin, 12. High-temperature cooling water outlet channel, 13. High-temperature refrigerant outlet channel, 14. Low-temperature refrigerant outlet channel, 15. Low-temperature cooling water inlet channel, 16. High-temperature refrigerant inlet channel, 17. Bottom plate, 2. Agent-side joint, 22. First medium-temperature heat exchange channel, 23. Second medium-temperature heat exchange channel, 3. Mounting plate, 31. Cooling water inlet channel, 32. Cooling water outlet channel, 33. First transition channel, 34. Second transition channel, 35. First straight-through channel, 36. First low-temperature heat exchange plate, 361. First separating rib, 362. Second separating rib, 363. Embedded groove, 37. Second low-temperature heat exchange plate, 4. Connector pipe, 5. Top plate, 6. Expansion valve, 7. Press block, 8. Marking part, 9. First partition plate, 10. Second partition plate, A. High-temperature heat exchange zone, B. Medium-temperature heat exchange zone, C. Low-temperature heat exchange zone DETAILED DESCRIPTION

[0032] The technical solutions in the embodiments of the present invention will be described clearly and completely below with reference to the accompanying drawings in the embodiments of the present invention.

[0033] In an automotive thermal management system, the compressor, water-cooled condenser, intermediate heat exchanger, chiller, refrigerant, and cooling water all work together to control the temperature of the vehicle's components. Specifically, the compressor is one of the core components of an automotive thermal management system. Its primary function is to compress low-temperature, low-pressure refrigerant gas into high-temperature, high-pressure refrigerant gas, increasing the refrigerant's pressure and temperature and providing power for the refrigerant's circulation within the system. For example, when a car's air conditioning system is turned on, the compressor starts, drawing in low-temperature, low-pressure refrigerant vapor from the evaporator. After compression, it is discharged as high-temperature, high-pressure refrigerant vapor, preparing for the subsequent heat exchange process.

[0034] The function of a water-cooled condenser is to cool and condense high-temperature, high-pressure refrigerant gas into liquid refrigerant. During this process, the refrigerant transfers heat to the cooling water, dissipating the heat. After entering the water-cooled condenser, the high-temperature, high-pressure refrigerant gas flows through the condenser's pipes. Cooling water flows outside the condenser's casing or pipes, exchanging heat with the refrigerant. Because the cooling water is relatively cold, the heat from the refrigerant gas is absorbed by the cooling water, lowering its temperature and condensing it into liquid refrigerant. For example, while a car is driving, the heat generated by the engine is dissipated by the cooling water circulating in the cooling system. The water-cooled condenser in the air conditioning system uses this cooling water to cool the refrigerant, dissipating the heat from the air conditioning system to the outside environment.

[0035] A chiller is primarily used to cool other fluids in a vehicle, such as battery coolant or engine coolant. It lowers the temperature of these fluids through heat exchange between the refrigerant and the chiller, ensuring the normal operating temperature of related components. As the low-temperature, low-pressure refrigerant flows through the chiller, it absorbs heat from the battery coolant or other fluids passing through it, lowering their temperature. As the refrigerant absorbs heat, its temperature rises, and its state may change from liquid to gas or a mixture of gas and liquid before returning to the compressor for the next cycle. For example, in electric vehicles, the chiller transfers heat generated by the battery to the refrigerant, preventing overheating and thereby extending the battery's lifespan and ensuring stable performance.

[0036] Intermediate heat exchangers (ICEs) perform heat exchange and energy regulation within a system. They transfer heat between refrigerants or other fluids in different circuits, optimizing system performance and efficiency. For example, in complex thermal management systems, they transfer heat from a high-temperature circuit to a low-temperature circuit, enabling energy recovery and reuse.

[0037] In the existing technology, the water-cooled condenser, intermediate heat exchanger, and chiller are all independent heat exchangers. Each of the three heat exchangers is independent and has its own shell, pipes and other structures. They need to be arranged separately in the limited space of the car, which will occupy a lot of space and is not conducive to the effective use of the car's interior space. This is especially difficult for small cars or new energy vehicles where batteries and other components already occupy a large amount of space.

[0038] The independent structure means that each heat exchanger has its own supporting and fixing components, and the overall weight is relatively large. This will increase the curb weight of the vehicle, which in turn affects the vehicle's fuel economy or the range of electric vehicles. For modern cars that pursue lightweighting to improve performance and efficiency, the extra weight is a disadvantage. The independent production of three heat exchangers requires separate investment in production equipment, molds and other resources. The production process is relatively complex and the number of parts is large, resulting in increased manufacturing costs. In addition, during the vehicle assembly process, the three heat exchangers need to be installed, pipes and lines connected separately. The installation process is cumbersome, increasing labor costs and installation time. The complex installation process may also increase the probability of failure.

[0039] Independent heat exchangers need to be connected through pipes, valves and other components, which makes the piping layout of the entire thermal management system complex and increases the length of the pipes. This not only increases the risk of system leakage, but also increases the difficulty of troubleshooting and repairing once a fault occurs. At the same time, complex systems place higher demands on the control strategy of the thermal management system. It is necessary to coordinate the work of multiple independent components to achieve the overall optimal thermal management effect, which increases the complexity and implementation difficulty of the control algorithm. Because the three heat exchangers are independent of each other, there may be a lot of heat loss during the heat transfer process, and it is difficult to achieve efficient heat recovery and utilization. For example, the heat generated by the cooling of the refrigerant in the water-cooled condenser cannot be easily utilized by the chiller or the intermediate heat exchanger, and the heat of different circuits cannot be flexibly allocated and optimized, which reduces the energy utilization efficiency of the entire thermal management system.

[0040] Therefore, in order to solve the above technical problems, Figure 1-9 As shown, the following technical solution is provided: an integrated heat exchanger module of an automobile thermal management system, comprising a high-temperature heat exchange zone A, a medium-temperature heat exchange zone B and a low-temperature heat exchange zone C stacked in sequence, a top plate 5 is installed on one side of the low-temperature heat exchange zone C, an expansion valve assembly is installed on the top plate 5, the high-temperature heat exchange zone A, the medium-temperature heat exchange zone B and the low-temperature heat exchange zone C are all composed of stacked plates 1, and adjacent plates 1 form alternating and independent first heat exchange channels and second heat exchange channels, wherein the high-temperature heat exchange zone A is equivalent to a water-cooled condenser, the medium-temperature heat exchange zone B is equivalent to an intermediate heat exchanger, and the low-temperature heat exchange zone Zone C is equivalent to a Chiller battery cooler. Different media flow through the first and second heat exchange channels, and heat exchange occurs between the different media. The media in the first and second heat exchange channels flow in opposite directions. In this embodiment, the high-temperature heat exchange zone A, the medium-temperature heat exchange zone B, and the low-temperature heat exchange zone C form an integrated structure. During installation, they are installed as a single component in the thermal management system and can be directly connected to the compressor and the water-side valve plate without the need for additional pipes. This allows the entire integrated heat exchanger module to be very small, and the thermal management integrated module can also be very small.

[0041] The plates 1 in the high-temperature heat exchange zone A, the medium-temperature heat exchange zone B, and the low-temperature heat exchange zone C are all arranged in pairs. In order to form the first and second heat exchange channels that are alternating and independent with each other, and to realize the shuttle circuit of the refrigerant in the three heat exchange zones, each pair of plates 1 has a slightly different structure. Specifically, in order to further realize the integration of the high-temperature heat exchange zone A, the medium-temperature heat exchange zone B, and the low-temperature heat exchange zone C, such as Figure 2-6As shown, the first heat exchange flow channel in the high-temperature heat exchange area A is connected to the low-temperature cooling water inlet channel 15 and the high-temperature cooling water outlet channel 12, and the second heat exchange flow channel in the high-temperature heat exchange area A is connected to the high-temperature refrigerant inlet channel 16 and the high-temperature refrigerant outlet channel 13. The high-temperature refrigerant inlet channel 16 is used to connect the high-temperature refrigerant from the compressor. Low-temperature cooling water circulates in the first heat exchange flow channel to perform heat exchange with the high-temperature refrigerant, which can reduce the temperature of the high-temperature refrigerant.

[0042] The first heat exchange channel in the medium-temperature heat exchange zone B is connected to the first medium-temperature heat exchange channels 22 located on both sides of the medium-temperature heat exchange zone B, and the second heat exchange channel in the medium-temperature heat exchange zone B is connected to the second medium-temperature heat exchange channels 23 located on both sides of the medium-temperature heat exchange zone B, which can further reduce the temperature of the high-temperature refrigerant while increasing the temperature of the low-temperature refrigerant returning from the low-temperature heat exchange zone C;

[0043] The first heat exchange channel in the low-temperature heat exchange zone C is connected to the cooling water inlet channel 31 and the cooling water outlet channel 32, and the second heat exchange channel in the low-temperature heat exchange zone C is connected to the first transition channel 33 and the second transition channel 34. The first transition channel 33 is connected to the outlet of the expansion valve assembly, and the second transition channel 34 is connected to one of the second medium-temperature heat exchange channels 23. The other second medium-temperature heat exchange channel 23 is connected to the low-temperature refrigerant outlet channel 14 in the high-temperature heat exchange zone A. In the low-temperature heat exchange zone C, the low-temperature and low-pressure refrigerant after the pressure is reduced by the expansion valve assembly is exchanged with the cooling water entering from the cooling water inlet channel 31, absorbs the heat of the cooling water, and completely evaporates into a low-temperature and low-pressure gaseous refrigerant;

[0044] One of the first medium-temperature heat exchange channels 22 is connected to the high-temperature refrigerant outlet channel 13, and the other first medium-temperature heat exchange channel 22 is connected to the first straight through channel 35 in the low-temperature heat exchange zone C, and the first straight through channel 35 is connected to the inlet of the expansion valve assembly.

[0045] As a specific working principle in this embodiment:

[0046] High-temperature refrigerant path (high-pressure side): The refrigerant is discharged from the compressor and enters the high-temperature heat exchange area A in the form of high-temperature and high-pressure gas, that is, enters the high-temperature refrigerant inlet channel 16, and then flows along the second heat exchange flow channel to the high-temperature refrigerant outlet channel 13. At the same time, the low-temperature coolant enters the high-temperature heat exchange area A from the low-temperature cooling water inlet channel 15, and the low-temperature coolant flows along the first heat exchange flow channel to the high-temperature cooling water outlet channel 12. In this process, the high-temperature and high-pressure gaseous refrigerant is gradually condensed into a high-temperature and high-pressure liquid through heat dissipation (water cooling).

[0047] Medium-temperature refrigerant path (high-pressure side, before expansion valve throttling): the high-temperature and high-pressure liquid refrigerant coming out of the high-temperature heat exchange zone A enters one of the first medium-temperature heat exchange channels 22, flows along the first heat exchange channel to the first medium-temperature heat exchange channel 22, and the low-temperature refrigerant coming out of the low-temperature heat exchange zone C flows between the second heat exchange channels between the two second medium-temperature heat exchange channels 23. Therefore, before reaching the expansion valve, the high-temperature and high-pressure liquid refrigerant exchanges heat with the low-temperature refrigerant coming out of the low-temperature heat exchange zone C in the medium-temperature heat exchange zone B, so that it is further cooled and the supercooling degree is increased; at the same time, the low-temperature refrigerant coming out of the low-temperature heat exchange zone C exchanges heat with the high-temperature and high-pressure liquid refrigerant coming out of the high-temperature heat exchange zone A in the medium-temperature heat exchange zone B, and its temperature is further increased before entering the compressor, thereby increasing the superheat degree. The medium-temperature heat exchange zone B greatly improves the system efficiency.

[0048] After being further cooled in the medium-temperature heat exchange zone B, the medium-temperature liquid refrigerant directly enters the first straight through channel 35. The first straight through channel 35 is not connected with the first heat exchange flow channel and the second heat exchange flow channel of the low-temperature heat exchange zone C. Its function is that of a flow hole. The medium-temperature liquid refrigerant directly enters the expansion valve assembly. The medium-temperature liquid refrigerant is throttled by the electronic expansion valve, and the pressure drops suddenly. Part of the liquid flashes into gas, forming a low-temperature and low-pressure two-phase mixed state, and then enters the first transition channel 33 of the low-temperature heat exchange zone C from the outlet of the expansion valve assembly.

[0049] Low-temperature refrigerant path (evaporation and heat absorption on the low-pressure side): After being throttled by the electronic expansion valve, the refrigerant enters the low-temperature heat exchange zone C and flows along the second heat exchange channel from the first transition channel 33 to the second transition channel 34. Simultaneously, external high-temperature battery coolant or engine coolant enters the cooling water inlet channel 31 and flows along the first heat exchange channel to the cooling water outlet channel 32. During this process, the low-temperature, low-pressure refrigerant absorbs heat from the external high-temperature battery coolant or engine coolant, completely evaporating into a low-temperature, low-pressure gaseous refrigerant. After exiting, the low-temperature, low-pressure gaseous refrigerant enters the medium-temperature heat exchange zone B through the second transition channel 34, exchanging heat with the high-temperature refrigerant from the high-temperature heat exchange zone A, further superheating. The gaseous refrigerant from the medium-temperature heat exchange zone B enters the low-temperature refrigerant outlet channel 14, passes directly through the high-temperature heat exchange zone A (without heat exchange), and returns to the compressor, completing the cycle.

[0050] In this embodiment, a first partition 9 is provided between the high-temperature heat exchange zone A and the medium-temperature heat exchange zone B, and a second partition 10 is provided between the medium-temperature heat exchange zone B and the low-temperature heat exchange zone C. By providing the first partition 9 and the second partition 10, the three heat exchange zones can be separated, and the corresponding channels that need to be isolated can also be isolated. For example, the first partition 9 isolates the high-temperature refrigerant inlet channel 16 and the first medium-temperature heat exchange channel 22, and the second partition 10 isolates the first medium-temperature heat exchange channel 22, the second medium-temperature heat exchange channel 23 and the cooling water inlet channel 31.

[0051] To improve heat exchange efficiency, fins 11 are installed in both the first and second heat exchange channels. These fins significantly increase the contact area between the fluid and the plates, enabling more efficient heat transfer. Fins increase the rigidity and strength of the plates, enabling them to withstand higher pressures and stresses. Fins 11 come in a variety of shapes, with common ones including straight fins, corrugated fins, and serrated fins. Straight fins are simple and easy to manufacture; corrugated fins increase fluid turbulence through their unique corrugated shape, improving heat exchange efficiency; and serrated fins, with their serrated edges, further enhance fluid turbulence. The fin shape can be selected based on your needs.

[0052] As another measure, rows of corrugated grooves can be provided on the surface of the plates, which also greatly increases the contact area between the fluid and the plates. Taking the common herringbone corrugated plates as an example, their unique corrugated shape increases the contact area between the fluid and the plates several times compared to flat plates when flowing between the plates, thereby more effectively transferring heat and improving heat exchange efficiency, and can be used to replace fins.

[0053] In this embodiment, as shown in 3-4, the expansion valve assembly includes a pressure block 7 installed on the top plate 5 and an expansion valve 6 installed at one end of the pressure block 7. The first straight-through channel 35 and the first transition channel 33 are respectively connected to the inner sides of the two ends of the pressure block 7. The expansion valve 6 is integrated into the heat exchanger through the pressure block 7, and the pressure block 7 can also serve as a valve seat to limit the inlet and outlet, thereby facilitating docking with the first straight-through channel 35 and the first transition channel 33.

[0054] In this embodiment, if Figure 4 As shown, the low-temperature cooling water inlet channel 15 and the high-temperature cooling water outlet channel 12 are located at a pair of diagonally opposite corners of the high-temperature heat exchange zone A, and the high-temperature refrigerant inlet channel 16 and the high-temperature refrigerant outlet channel 13 are located at another pair of diagonally opposite corners of the high-temperature heat exchange zone A, which can effectively utilize the space of the high-temperature heat exchange zone A to increase the efficiency of heat exchange.

[0055] Similarly, as a channel setting method, such as Figure 4As shown, the first transition channel 33 and the second transition channel 34 are arranged side by side on one side of the low-temperature heat exchange zone C, and the cooling water inlet channel 31 and the cooling water outlet channel 32 are arranged side by side on the other side of the low-temperature heat exchange zone C. The plates in the low-temperature heat exchange zone C include first and second low-temperature heat exchange plates 36 and 37 that are staggered and stacked, wherein the first low-temperature heat exchange plate 36 is provided with a first dividing rib 361 at a position between the first transition channel 33 and the second transition channel 34, and the second low-temperature heat exchange plate 37 is provided with a second dividing rib 362 that cooperates with the first dividing rib 361 at a position between the cooling water inlet channel 31 and the cooling water outlet channel 32. The first dividing rib 361 is embedded in the embedded groove 363 in the middle of the second dividing rib 362. At this time, the position where the first dividing rib 361 and the embedded groove 363 are inserted into the flow is blocked, and the first dividing rib 361 is embedded in other positions of the second dividing rib 362 to allow flow. At the same time, by setting the first separating rib 361 and the second separating rib 362, U-shaped and opposite flow channels can be formed on the first heat exchange channel and the second heat exchange channel of the low-temperature heat exchange zone C respectively, which can improve the heat exchange efficiency between the cooling water and the low-temperature and low-pressure refrigerant. At the same time, the first transition channel 33 and the second transition channel 34 can also be concentrated in a position close to the expansion valve to facilitate the formation of a loop.

[0056] In this embodiment, a base plate 17 is installed on the side of the high-temperature heat exchange zone A, and a mounting plate 3 is connected to the outer side of the base plate 17. The mounting plate 3 is provided with an agent side joint 2 connected to the high-temperature refrigerant inlet channel 16 and the low-temperature refrigerant outlet channel 14. By providing the mounting plate 3, it is convenient to directly connect the integrated heat exchanger module with the compressor, and the agent side joint 2 is convenient to connect with the refrigerant inlet and outlet of the compressor.

[0057] In this embodiment, a joint pipe 4 connected to the cooling water inlet channel 31 and the cooling water outlet channel 32 is installed on the top plate 5. The top plate 5 is conducive to sealing the low-temperature heat exchange area C.

[0058] like Figure 1 As shown, the edges of the plates, first baffle 9, and second baffle 10 are all provided with protruding marking portions 8, and the positions of the marking portions 8 on the high-temperature heat exchange zone A, medium-temperature heat exchange zone B, low-temperature heat exchange zone C, first baffle 9, and second baffle 10 are all different. By providing marking portions 8 in different positions, the high-temperature heat exchange zone A, medium-temperature heat exchange zone B, low-temperature heat exchange zone C, first baffle 9, and second baffle 10 can be quickly distinguished, facilitating installation without the problem of incorrect installation. Among them, the plates, first baffle 9, second baffle 10, bottom plate 17, and top plate 5 are brazed together, and the assembly is firm and reliable.

[0059] Therefore, through the application of this embodiment, the refrigerant channels of the water-cooled condenser, the water-refrigerant heat exchange layer of the intermediate heat exchanger, and the water-water heat exchange layer of the chiller are integrated into the same housing, reducing the number of connection points by 70%. The volume of the automotive thermal management integrated module is reduced by more than 40%, while 90% of the external piping is eliminated. The integrated design optimizes the path through internal thermal coupling. The weight of the individual components of the traditional solution is about 5kg, but after integration, it can be reduced to 2-3kg.

[0060] It should be noted that all directional indications in the embodiments of the present invention (such as up, down, left, right, front, back, etc.) are only used to explain the relative position relationship, movement status, etc. between the various components under a certain specific posture (as shown in the accompanying drawings). If the specific posture changes, the directional indication will also change accordingly.

[0061] In addition, the terms "first," "second," and so on, used in this disclosure are for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of the technical features being described. Thus, a feature specified as "first" or "second" may explicitly or implicitly include at least one such feature. In the description of this disclosure, "plurality" means at least two, such as two, three, etc., unless otherwise specifically defined.

[0062] In the present invention, unless otherwise specified or limited, the terms "connection" and "fixation" should be understood in a broad sense. For example, "fixation" can mean fixed connection, detachable connection, or integration; mechanical connection or electrical connection; direct connection or indirect connection through an intermediate medium; internal communication between two elements or interaction between two elements, unless otherwise specified. Those skilled in the art will be able to understand the specific meanings of the above terms in the present invention based on specific circumstances.

[0063] In addition, the technical solutions between the various embodiments of the present invention can be combined with each other, but it must be based on the fact that ordinary technicians in this field can implement it. When the combination of technical solutions is mutually contradictory or cannot be implemented, it should be deemed that such a combination of technical solutions does not exist and is not within the scope of protection required by the present invention.

Claims

1. An integrated heat exchanger module for an automotive thermal management system, comprising a top plate and an expansion valve assembly mounted on the top plate, characterized in that: One side of the top plate includes a low-temperature heat exchange zone, a medium-temperature heat exchange zone and a high-temperature heat exchange zone stacked in sequence, wherein the high-temperature heat exchange zone, the medium-temperature heat exchange zone and the low-temperature heat exchange zone are all composed of stacked plates, and adjacent plates form alternating and independent first heat exchange channels and second heat exchange channels; The first heat exchange channel in the high-temperature heat exchange zone is connected to the low-temperature cooling water inlet channel and the high-temperature cooling water outlet channel, and the second heat exchange channel in the high-temperature heat exchange zone is connected to the high-temperature refrigerant inlet channel and the high-temperature refrigerant outlet channel; The first heat exchange channel in the medium temperature heat exchange zone is connected to the first medium temperature heat exchange channels located on both sides of the medium temperature heat exchange zone, and the second heat exchange channel in the medium temperature heat exchange zone is connected to the second medium temperature heat exchange channels located on both sides of the medium temperature heat exchange zone; The first heat exchange channel in the low-temperature heat exchange zone is connected to the cooling water inlet channel and the cooling water outlet channel, the second heat exchange channel in the low-temperature heat exchange zone is connected to the first transition channel and the second transition channel, the first transition channel is connected to the outlet of the expansion valve assembly, the second transition channel is connected to one of the second medium-temperature heat exchange channels, and the other second medium-temperature heat exchange channel is connected to the low-temperature refrigerant outlet channel in the high-temperature heat exchange zone; One of the first medium-temperature heat exchange channels is connected to the high-temperature refrigerant outlet channel, and the other first medium-temperature heat exchange channel is connected to the first straight through channel in the low-temperature heat exchange zone, and the first straight through channel is connected to the inlet of the expansion valve assembly; The expansion valve assembly includes a compression block mounted on the top plate and an expansion valve mounted at one end of the compression block, and the first straight through channel and the first transition channel are respectively connected to the inner sides of both ends of the compression block; The low-temperature cooling water inlet channel and the high-temperature cooling water outlet channel are located at a pair of diagonally opposite corners of the high-temperature heat exchange zone, and the high-temperature refrigerant inlet channel and the high-temperature refrigerant outlet channel are located at another pair of diagonally opposite corners of the high-temperature heat exchange zone; The first transition channel and the second transition channel are arranged side by side on one side of the low-temperature heat exchange zone, and the cooling water inlet channel and the cooling water outlet channel are arranged side by side on the other side of the low-temperature heat exchange zone. The plates in the low-temperature heat exchange zone include first low-temperature heat exchange plates and second low-temperature heat exchange plates that are staggered and stacked, wherein a first separating rib is provided on the first low-temperature heat exchange plate at a position between the first transition channel and the second transition channel, and a second separating rib that cooperates with the first separating rib is provided on the second low-temperature heat exchange plate at a position between the cooling water inlet channel and the cooling water outlet channel, and the first separating rib is embedded in the embedding groove in the middle part of the second separating rib.

2. The integrated heat exchanger module for an automotive thermal management system according to claim 1, characterized in that: A first partition is provided between the high-temperature heat exchange zone and the medium-temperature heat exchange zone, and a second partition is provided between the medium-temperature heat exchange zone and the low-temperature heat exchange zone.

3. The integrated heat exchanger module for an automotive thermal management system according to claim 2, characterized in that: Fins are installed in the first heat exchange channel and the second heat exchange channel.

4. The integrated heat exchanger module for an automotive thermal management system according to claim 1, characterized in that: A bottom plate is installed on the side of the high-temperature heat exchange zone, a mounting plate is connected to the outside of the bottom plate, and an agent-side joint connected to the high-temperature refrigerant inlet channel and the low-temperature refrigerant outlet channel is installed on the mounting plate.

5. The integrated heat exchanger module for an automotive thermal management system according to claim 4, characterized in that: A joint pipe connected with the cooling water inlet channel and the cooling water outlet channel is installed on the top plate.

6. The integrated heat exchanger module for an automotive thermal management system according to claim 2, characterized in that: The edges of the plates, the first partition and the second partition are all provided with protruding marking parts, and the positions of the marking parts on the high-temperature heat exchange zone, the medium-temperature heat exchange zone, the low-temperature heat exchange zone, the first partition and the second partition are all different.

7. The integrated heat exchanger module for an automotive thermal management system according to claim 6, characterized in that: The plates, the first partition plate, the second partition plate, the bottom plate and the top plate are connected by brazing.

Images