ORC-based thermal management system

Abstract

The utility model relates to a thermal management system based on ORC, the thermal management system based on ORC comprises a generator, a power element, an evaporator, a turbine, a condenser, a working medium storage tank and a liquid pump, the evaporator, the turbine, the condenser, the working medium storage tank and the liquid pump are sequentially communicated through a pipeline, a liquid working medium is arranged in the evaporator, and the power element is at least partially immersed in the liquid working medium; the liquid working medium can absorb heat in the evaporator to be gasified and enter the turbine to drive the turbine to drive the generator to operate and generate electricity, the condenser can enable the gaseous working medium to release heat to be liquefied and enter the working medium storage tank, and the liquid pump can drive the liquid working medium in the working medium storage tank to flow back into the evaporator. According to the ORC-based thermal management system provided by the invention, the following defects in the existing heat dissipation technology are overcome: the heat dissipation effect is not uniform, so that local overheating of a power element is possibly caused; the heat dissipation efficiency is greatly influenced by the environment temperature, and the performance is obviously reduced in a high-temperature environment; effective utilization of heat generated in the heat dissipation process is difficult to achieve.

Description

Technical Field

[0001] This application relates to the field of waste heat recovery equipment technology, and in particular to a thermal management system based on ORC. Background Technology

[0002] The Organic Rankine Cycle (ORC) is an ideal circulating process that uses low-boiling-point organic compounds as the working fluid. It is primarily used to recover waste heat from medium- and low-temperature heat sources, converting thermal energy into electrical energy. An ORC system typically consists of an evaporator, expander, generator, condenser, and working fluid pump. In addition, the entire ORC system may include auxiliary equipment such as working fluid storage tanks, valves, piping, and control systems to ensure stable operation and safe operation.

[0003] With the rapid development of the new energy industry, power components such as batteries, chips, and IGBTs are becoming smaller and their power density is increasing, which in turn raises the requirements for heat dissipation and temperature uniformity. Traditional cooling technologies typically connect at least part of the power component's surface to a liquid cooling plate or the evaporator section of a heat pipe heat exchanger using thermally conductive silicone grease or other interface materials for heat dissipation. However, this method suffers from low heat dissipation efficiency and cannot meet the heat dissipation needs of high-power-density components.

[0004] Furthermore, existing heat dissipation methods typically release lost heat directly into the atmosphere or liquid environments such as rivers, lakes, and seas, making it impossible to recover and reuse it. This not only wastes energy but also contradicts the current trend of energy conservation and emission reduction. With increasing environmental awareness and ever-rising requirements for energy efficiency, how to recover and reuse the heat generated by power components has become an urgent problem to be solved.

[0005] Existing heat dissipation technologies still have the following drawbacks: uneven heat dissipation, which may lead to local overheating of power components; heat dissipation efficiency is greatly affected by ambient temperature, and performance degrades significantly in high-temperature environments; and it is difficult to effectively utilize the heat generated during the heat dissipation process. Utility Model Content

[0006] Therefore, it is necessary to provide an ORC-based thermal management system to address the following shortcomings of existing heat dissipation technologies: uneven heat dissipation, which may lead to local overheating of power components; heat dissipation efficiency is greatly affected by ambient temperature, and performance degrades significantly in high-temperature environments; and it is difficult to effectively utilize the heat generated during the heat dissipation process.

[0007] The ORC-based thermal management system provided in this application includes a generator, power elements, and an evaporator, a turbine, a condenser, a working fluid storage tank, and a liquid pump connected in sequence by pipelines. The evaporator contains a liquid working fluid, and the power elements are at least partially immersed in the liquid working fluid. The liquid working fluid can absorb heat and vaporize in the evaporator and enter the turbine to drive the turbine to drive the generator to operate and generate electricity. The condenser can release heat and liquefy the gaseous working fluid and let it enter the working fluid storage tank. The liquid pump can drive the liquid working fluid in the working fluid storage tank to flow back to the evaporator.

[0008] In one embodiment, the evaporator includes a first housing, a second housing, and a first sealing flange. The second housing has a receiving cavity with an installation opening, through which a power element is installed. The first housing is detachably installed at the installation opening of the first housing via the first sealing flange and seals the receiving cavity.

[0009] In one embodiment, the evaporator further includes an insulating support through which the power element is detachably mounted to a receiving cavity of the second housing.

[0010] In one embodiment, the evaporator further includes a second sealing flange that is sealed to the side wall of the second housing, through which the power components can be electrically connected to external devices.

[0011] In one embodiment, the second sealing flange includes a mounting collar, an insulating mounting plate, and conductive posts. The mounting collar is sleeved on the outer periphery of the insulating mounting plate, and the second sealing flange can be sealed and installed on the side wall of the second housing through the mounting collar. Multiple conductive posts are spaced apart, and each conductive post is sealed and passed through both ends of the insulating mounting plate, so that the power element can be electrically connected to external equipment through the corresponding conductive post.

[0012] In one embodiment, multiple conductive pillars are arranged in an array on an insulating mounting plate.

[0013] In one embodiment, the mounting collar is detachably mounted to the side wall of the second housing via fasteners.

[0014] In one embodiment, the ORC-based thermal management system further includes a gas-liquid separator disposed within the working fluid storage tank, so that the working fluid in a gas-liquid mixture passing through the condenser can be separated by the gas-liquid separator.

[0015] In one embodiment, the ORC-based thermal management system further includes a first multi-way valve, a second multi-way valve, and a service pipe. The first multi-way valve connects the evaporator and the turbine, the second multi-way valve connects the turbine and the condenser, and the service pipe connects the first multi-way valve and the second multi-way valve.

[0016] In one embodiment, the thermal management system further includes a replenishment and venting valve disposed at the upper end of the working fluid storage tank for replenishing the working fluid into the working fluid storage tank and for venting excess gas from the working fluid storage tank.

[0017] Compared with existing technologies, the core innovation of the ORC-based thermal management system provided in this application lies in directly immersing the power components in the liquid working fluid within the evaporator. This direct contact achieves efficient heat dissipation, preventing performance degradation of the power components under high-temperature environments. Furthermore, the heat dissipation is highly uniform, preventing localized overheating of the power components. Simultaneously, the organic Rankine cycle principle is utilized to convert dissipated heat into electrical energy, achieving heat recovery and utilization. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of this application or the conventional technology, the drawings used in the description of the embodiments or the conventional technology will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 A schematic diagram of the system architecture of an ORC-based thermal management system provided in this application;

[0020] Figure 2 A schematic diagram of the assembly structure of an evaporator and power element according to an embodiment of this application;

[0021] Figure 3 This is a schematic diagram of the structure of a second sealing flange according to an embodiment of this application.

[0022] Reference numerals: 100, Cooling fan; 200, Generator; 300, Evaporator; 310, First housing; 320, Second housing; 330, First sealing flange; 340, Insulating bracket; 350, Second sealing flange; 351, Mounting collar; 352, Insulating mounting plate; 353, Conductive post; 354, Fastener; 400, Turbine; 500, Condenser; 600, Working fluid storage tank; 610, Liquid replenishment and venting valve; 700, Liquid pump; 800, Power element; 910, First multi-way valve; 920, Second multi-way valve; 930, Inspection pipe. Detailed Implementation

[0023] The Organic Rankine Cycle (ORC) is an ideal circulating process that uses low-boiling-point organic compounds as the working fluid. It is primarily used to recover waste heat from medium- and low-temperature heat sources, converting thermal energy into electrical energy. An ORC system typically consists of an evaporator, expander, generator, condenser, and working fluid pump. In addition, the entire ORC system may include auxiliary equipment such as working fluid storage tanks, valves, piping, and control systems to ensure stable operation and safe operation.

[0024] With the rapid development of the new energy industry, power components such as batteries, chips, and IGBTs are becoming smaller and their power density is increasing, which in turn raises the requirements for heat dissipation and temperature uniformity. Traditional cooling technologies typically connect at least part of the power component's surface to a liquid cooling plate or the evaporator section of a heat pipe heat exchanger using thermally conductive silicone grease or other interface materials for heat dissipation. However, this method suffers from low heat dissipation efficiency and cannot meet the heat dissipation needs of high-power-density components.

[0025] Furthermore, existing heat dissipation methods typically release lost heat directly into the atmosphere or liquid environments such as rivers, lakes, and seas, making it impossible to recover and reuse it. This not only wastes energy but also contradicts the current trend of energy conservation and emission reduction. With increasing environmental awareness and ever-rising requirements for energy efficiency, how to recover and reuse the heat generated by power components has become an urgent problem to be solved.

[0026] Existing heat dissipation technologies still have the following drawbacks: uneven heat dissipation, which may lead to local overheating of power components; complex heat dissipation system structure and high maintenance costs; heat dissipation efficiency is greatly affected by ambient temperature, and performance degrades significantly in high-temperature environments; and it is difficult to effectively utilize the heat generated during the heat dissipation process.

[0027] To address the aforementioned issues, existing technologies urgently need improvement.

[0028] In exploring solutions to the technical problems of low heat dissipation efficiency and heat recovery in power components, this application first considers the limitations of traditional cooling technologies. Traditional methods typically connect the surface of the power component to the heat dissipation device via a thermally conductive material; this indirect contact method limits heat transfer efficiency. Therefore, this application raises a key question: how to increase the direct contact area between the power component and the cooling medium.

[0029] After careful consideration, this application proposes an innovative solution that involves directly immersing power components in a liquid working fluid. This direct contact method significantly improves heat dissipation efficiency and solves the interfacial thermal resistance problem in traditional methods. However, simply improving heat dissipation efficiency is not enough to completely solve the problem; it is also necessary to consider how to effectively utilize the dissipated heat.

[0030] Based on this idea, this application further explores the possibility of combining the heat dissipation process with heat recovery. The Organic Rankine Cycle (ORC), as a mature low-temperature waste heat recovery technology, has become an ideal choice. By combining power component heat dissipation with an ORC system, not only can efficient heat dissipation be achieved, but thermal energy can also be converted into useful electrical energy.

[0031] Please see Figures 1-3 Specifically, this application designs a closed-loop system including an evaporator 300, a turbine 400, a condenser 500, a working fluid storage tank 600, and a liquid pump 700. The power element 800 is placed in the liquid working fluid within the evaporator 300 to ensure maximum heat transfer efficiency. When the liquid working fluid absorbs heat and vaporizes, it drives the turbine 400, which in turn drives the generator 200 to generate electricity, thus converting thermal energy into electrical energy.

[0032] However, during the system design process, this application also faced the challenge of improving the overall system efficiency. Analysis revealed that heat loss in the piping is a significant factor affecting system efficiency. To address this issue, this application proposes an innovative design that maintains the piping at a high vacuum level below 100 Pa. This high vacuum environment can significantly reduce heat loss and further improve the system's thermal efficiency.

[0033] Through this series of problem analyses and solution optimizations, this application ultimately yielded a complete technical solution for a thermal management system based on ORC. This system not only solves the problem of efficient heat dissipation for the 800 power element but also achieves effective heat recovery and utilization. Furthermore, the high-vacuum piping design improves the overall system efficiency.

[0034] Therefore, as Figure 1 As shown, this application proposes a thermal management system based on ORC, including a generator 200, a power element 800, and an evaporator 300, a turbine 400, a condenser 500, a working fluid storage tank 600, and a liquid pump 700 connected in sequence by pipelines. The evaporator 300 contains a liquid working fluid, and the power element 800 is at least partially immersed in the liquid working fluid. The liquid working fluid can absorb heat and vaporize in the evaporator 300 and enter the turbine 400 to drive the turbine 400 to drive the generator 200 to run and generate electricity. The condenser 500 can release heat and liquefy the gaseous working fluid and let it enter the working fluid storage tank 600. The liquid pump 700 can drive the liquid working fluid in the working fluid storage tank 600 to flow back into the evaporator 300.

[0035] Furthermore, in one embodiment, the ORC thermal management system also includes a cooling fan 100 positioned directly opposite the condenser 500 to accelerate heat dissipation from the condenser 500.

[0036] Among them, generator 200 refers to a device that converts mechanical energy into electrical energy, which can be implemented by synchronous generator 200 or asynchronous generator 200.

[0037] Among them, power element 800 refers to high-power semiconductor devices used in power electronic systems, which can be implemented using IGBTs, MOSFETs or SiC, etc.

[0038] Evaporator 300 refers to a heat exchange device used to heat and vaporize liquid working fluid, which can be implemented using shell-and-tube or plate heat exchangers.

[0039] Among them, turbine 400 refers to a power machine that uses gas expansion to do work, which can be implemented by axial flow or radial flow turbine 400.

[0040] The condenser 500 refers to a heat exchange device used to cool and liquefy a gaseous working fluid, which can be implemented by using an air-cooled or water-cooled condenser 500.

[0041] Among them, the working medium storage tank 600 refers to a container used to store liquid working medium, which can be implemented by pressure vessel or atmospheric pressure storage tank.

[0042] Among them, the liquid pump 700 refers to a device used to transport liquid working fluid, which can be implemented by a centrifugal pump or a gear pump.

[0043] The core innovation of this application lies in directly immersing the power element 800 in the liquid working fluid within the evaporator 300, achieving efficient heat dissipation through direct contact. Simultaneously, utilizing the organic Rankine cycle principle, the dissipated heat is converted into electrical energy, achieving heat recovery and utilization.

[0044] The working principle of this application is as follows:

[0045] The evaporator 300 is made of high-temperature and corrosion-resistant metal and contains a liquid working fluid. The power unit 800 is fixed within the evaporator 300 using a specific mounting structure and is at least partially immersed in the liquid working fluid. The turbine 400, condenser 500, working fluid storage tank 600, and liquid pump 700 are sequentially connected via pipelines to form a closed-loop system. The pipelines utilize special materials and sealing technology to maintain a high vacuum level below 100 Pa.

[0046] When power element 800 operates, the heat generated is directly transferred to the liquid working fluid. The liquid working fluid absorbs the heat and rapidly vaporizes, then enters turbine 400 through pipelines. The turbine 400 impeller rotates at high speed under the pressure of the gas, driving the rotor of generator 200, which is coaxially connected to it, to rotate, thereby generating electricity.

[0047] The low-pressure gaseous working fluid from the turbine 400 outlet enters the condenser 500, where it releases heat and liquefies. The liquefied working fluid flows into the working fluid storage tank 600 for temporary storage. The liquid pump 700 pressurizes the liquid working fluid in the working fluid storage tank 600 and sends it back to the evaporator 300, completing one cycle.

[0048] The design of the power element 800, directly immersed in the liquid working fluid, significantly increases the heat transfer area, reduces thermal resistance, and improves heat dissipation efficiency. The selection of high-vacuum piping minimizes heat loss and enhances the overall thermal efficiency of the system. The choice of working fluid considers its thermophysical properties, environmental friendliness, and the system's operating temperature range to ensure efficient system operation.

[0049] As a preferred embodiment, the ORC-based thermal management system of this application can be applied to the power system of an electric vehicle. Specifically, the system includes a permanent magnet synchronous generator 200 with a rated power of 100kW, a set of IGBT modules with a total power of 200kW as power elements 800, and an evaporator 300, a turbine 400, a condenser 500, a working fluid storage tank 600, and a liquid pump 700, which are sequentially connected by stainless steel pipes with an inner diameter of 20mm and a wall thickness of 2mm.

[0050] Evaporator 300 is made of 316L stainless steel, with an internal volume of 10L, filled with 8L of R1234yf as the liquid working fluid. The IGBT module is fixed inside evaporator 300 by a specially designed insulating bracket 340, with an immersion depth of 50mm. Turbine 400 is a radial flow type with a rated speed of 30,000 rpm. Condenser 500 is air-cooled with a cooling area of ​​2m². 2 The working fluid storage tank 600 has a volume of 5L, and the liquid pump 700 is a magnetically driven centrifugal pump with a rated flow rate of 50L / min.

[0051] When the system starts up, the IGBT module begins to work, generating heat. Liquid R1234yf absorbs this heat and begins to vaporize. The gaseous working fluid enters turbine 400 at a pressure of 2 MPa, driving turbine 400 to rotate. Turbine 400 drives generator 200 to generate electricity, with an output voltage of 380V. After expanding and doing work in turbine 400, the gaseous working fluid's pressure drops to 0.5 MPa and its temperature drops to 40°C, entering condenser 500. In condenser 500, the working fluid is further cooled to 25°C and completely liquefied, flowing into working fluid storage tank 600. Liquid pump 700 pressurizes the liquid working fluid to 2.2 MPa and returns it to evaporator 300, completing one cycle.

[0052] The entire system's piping maintains a high vacuum of below 50 Pa to minimize heat loss. This design not only effectively dissipates the heat generated by the IGBT modules, keeping their operating temperature below 85°C, but also recovers approximately 15kW of electrical energy, significantly improving the overall energy efficiency of the power system.

[0053] In one embodiment, such as Figure 2 As shown, the evaporator 300 includes a first housing 310, a second housing 320 and a first sealing flange 330. The second housing 320 is provided with a receiving cavity having an installation opening. The power element 800 is installed in the receiving cavity through the installation opening. The first housing 310 is detachably installed at the installation opening of the first housing 310 through the first sealing flange 330 and seals the receiving cavity.

[0054] This technical solution addresses the installation and removal of the power element 800 by designing an evaporator 300 with a detachable structure. The evaporator 300 comprises a first housing 310, a second housing 320, and a first sealing flange 330. The second housing 320 has a receiving cavity and an installation opening, through which the power element 800 can be installed. The first housing 310 is detachably mounted at the installation opening via the first sealing flange 330, and it seals the receiving cavity. This design not only facilitates the installation and removal of the power element 800 but also ensures the system's airtightness, thereby improving heat dissipation efficiency and overall system performance.

[0055] Traditional stationary evaporator 300 structures typically require the power element 800 to be permanently fixed inside the evaporator 300, making maintenance and replacement very difficult. The detachable design of this application significantly improves the system's flexibility and maintainability. Furthermore, the design of this application allows for flexible adjustment of the housing cavity and mounting opening size according to different power element 800 dimensions and heat dissipation requirements—an adaptability difficult to achieve in traditional designs. Therefore, this application not only solves the installation and removal problems of the power element 800 but also improves the overall system performance and service life, demonstrating significant technological advancement.

[0056] In one embodiment, the evaporator 300 further includes an insulating support 340, through which the power element 800 is detachably mounted to the receiving cavity of the second housing 320.

[0057] This technical solution solves the problem of installing and removing the power element 800 in the evaporator 300 by adding an insulating support 340 to the evaporator 300 and detachably mounting the power element 800 in the receiving cavity of the second housing 320 via the insulating support 340. This design not only ensures electrical insulation between the power element 800 and the evaporator 300 housing but also improves the maintainability and flexibility of the system. The power element 800 can be easily installed and removed, facilitating maintenance and replacement, while maintaining good thermal contact with the liquid working fluid for efficient heat dissipation. Furthermore, this design may improve system safety and reduce the risk of electrical failures.

[0058] The insulating bracket 340 can be made of a variety of materials and structural designs. For example, it can be made of materials with good insulation and heat resistance, such as ceramics, high-temperature plastics, or composite materials. The shape of the insulating bracket 340 can be customized according to the specific size and installation requirements of the power element 800. It can be a simple flat structure or a complex structure with grooves or protrusions to better secure the power element 800.

[0059] The power element 800 can be connected to the insulating bracket 340 by bolt fixing, snap-fit ​​connection or other detachable connection methods. This detachable design allows the power element 800 to be easily removed from the evaporator 300 for inspection, maintenance or replacement when needed, without disassembling the entire evaporator 300 system.

[0060] The connection between the insulating bracket 340 and the receiving cavity of the second housing 320 can also be detachable, for example, by using bolts or snap-fit ​​connections. This not only facilitates the installation and removal of the entire power element 800-insulating bracket 340 assembly, but also allows for the replacement of the insulating bracket 340 itself when needed.

[0061] The power element 800 can directly contact the liquid working fluid, greatly improving heat dissipation efficiency; the insulating bracket 340 provides reliable electrical insulation; and the detachable design greatly simplifies the maintenance and replacement process. These improvements not only enhance system performance and safety but also significantly reduce maintenance costs and time.

[0062] In one embodiment, the evaporator 300 further includes a second sealing flange 350, which is sealed to the side wall of the second housing 320, and the power element 800 can be electrically connected to an external device through the second sealing flange 350.

[0063] The advantage of this design is that it ensures both effective heat dissipation for the power element 800 and electrical connection with external devices. Through the second sealing flange 350, the power element 800 can establish an electrical connection with external devices while maintaining good heat dissipation, thereby improving the overall performance and usability of the system.

[0064] Regarding material selection, the mounting collar 351 can be made of metals such as aluminum alloy, copper alloy, or stainless steel; the conductive post 353 can be made of metal strips such as aluminum or copper; and the insulating mounting plate 352 can be made of insulating ceramics or engineering plastics. These material choices ensure good conductivity, sealing, and insulation.

[0065] This design demonstrates significant advantages in practical applications. Since the power element 800 is directly immersed in the liquid working fluid, heat dissipation is greatly improved. Simultaneously, the electrical connection achieved through the second sealing flange 350 ensures the system's airtightness and the reliability of the electrical connection. Compared to traditional heat dissipation systems, this application's solution not only improves heat dissipation efficiency but also solves the problem of achieving electrical connection for the power element 800 in high-efficiency heat dissipation environments.

[0066] Furthermore, the design of this application also offers excellent maintainability. The power element 800 can be easily installed, replaced, and maintained via the detachable first sealing flange 330 and second sealing flange 350 without affecting the overall system's sealing performance. This design significantly improves the system's practicality and reliability.

[0067] In one embodiment, such as Figure 3 As shown, the second sealing flange 350 includes a mounting collar 351, an insulating mounting plate 352, and conductive posts 353. The mounting collar 351 is sleeved on the outer periphery of the insulating mounting plate 352. The second sealing flange 350 can be sealed and installed on the side wall of the second housing 320 through the mounting collar 351. Multiple conductive posts 353 are spaced apart, and each conductive post 353 is respectively sealed and passed through both ends of the insulating mounting plate 352, so that the power element 800 can be electrically connected to external equipment through the corresponding conductive post 353.

[0068] Compared to existing technologies, the second sealing flange 350 structure of this application offers significant advantages. Traditional electrical connection methods typically require additional sealing structures external to the system, increasing system complexity and leakage risk. In contrast, the design of this application integrates electrical connection and sealing functions into a compact structure, greatly simplifying system design and improving reliability. Furthermore, the design allows for convenient installation, maintenance, and replacement of the power element 800 while maintaining system sealing, which is of great significance in practical applications. Compared to traditional cable penetration methods, the multi-conducting post 353 design of this application provides higher current carrying capacity and better heat dissipation performance, making it particularly suitable for high power density applications.

[0069] In one embodiment, multiple conductive posts 353 are arranged in an array on the insulating mounting plate 352. This arrangement can effectively solve the problem of arranging the conductive posts 353 on the insulating mounting plate 352, which not only improves space utilization but also facilitates standardized design, optimizes electrical performance, and is beneficial for heat dissipation.

[0070] Specifically, the conductive posts 353 and the insulating mounting plate 352 are components of the second sealing flange 350. The conductive posts 353 enable the power element 800 to be electrically connected to external equipment. The insulating mounting plate 352 provides insulating support and allows the conductive posts 353 to pass through. Arranging multiple conductive posts 353 in an array on the insulating mounting plate 352 achieves the following effects:

[0071] First, array-style distribution can improve space utilization. Within the limited area of ​​the insulating mounting plate 352, a more conductive posts 353 can be accommodated through a reasonable array arrangement. For example, different arrangements such as rectangular, square, or hexagonal arrays can be used, and the most suitable layout can be selected according to actual needs. This arrangement allows for a more compact distribution of the conductive posts 353, thus enabling the installation of more conductive posts 353 on the same area of ​​the insulating mounting plate 352.

[0072] Secondly, the array-style distribution facilitates standardized design. Because the positions of the conductive posts 353 are regular, standardized design schemes can be more easily developed. For example, fixed row and column spacing can be set, allowing insulating mounting plates 352 of different specifications to adopt the same arrangement principle. This standardized design not only simplifies the design process but also improves production efficiency and reduces manufacturing costs.

[0073] Furthermore, the array-style distribution can optimize electrical performance. By rationally designing the spacing between the conductive posts 353, mutual interference between them can be reduced. For example, a minimum spacing can be set based on the diameter of the conductive posts 353 and the current magnitude to ensure that electromagnetic interference does not occur between them. Simultaneously, the array-style distribution can also make the current distribution more uniform, contributing to improved overall electrical performance.

[0074] Finally, the array-like distribution facilitates heat dissipation. Maintaining appropriate spacing between the conductive posts 353 creates heat dissipation channels, which is beneficial for heat dissipation. For example, gaps can be left between the conductive posts 353 to allow airflow or cooling liquid flow, thereby improving heat dissipation efficiency. This is especially important for high power density applications, as it can effectively prevent the conductive posts 353 from overheating.

[0075] However, this is not the only embodiment. In other embodiments, the multiple conductive pillars 353 may also be arranged in a concentric circle pattern.

[0076] In one embodiment, the mounting collar 351 is detachably mounted to the side wall of the second housing 320 by means of fastener 354.

[0077] The choice of 354 fasteners can be based on specific requirements. For example, different types of 354 fasteners such as bolts, screws, or clips can be used. Bolts and screws provide strong fixing force and are suitable for applications requiring frequent disassembly and assembly; while clips allow for quick disassembly and assembly and are suitable for applications requiring frequent inspection.

[0078] The mounting collar 351 can be made of metals such as aluminum alloy, copper alloy, or stainless steel. These materials have good strength and corrosion resistance, ensuring the long-term performance of the mounting collar 351. At the same time, these materials also have good thermal conductivity, which is beneficial for heat transfer and dissipation.

[0079] Compared with existing technologies, the detachable design of this application has significant advantages. Traditional fixed installation methods often require permanent connections such as welding or adhesives. While these methods ensure the strength of the connection, they present significant difficulties when maintenance or replacement is needed. The detachable design of this application, however, ensures both connection strength and greatly improves the maintainability and flexibility of the system. This design not only simplifies the maintenance process but also provides the possibility for long-term optimization and upgrades of the system, thereby significantly improving the service life and performance of the entire thermal management system.

[0080] However, this is not the only embodiment. In other embodiments, the mounting collar 351 may also be welded to the side wall of the second housing 320.

[0081] In one embodiment, the mounting collar 351 is made of metal materials such as aluminum alloy, copper alloy or stainless steel, the conductive post 353 is made of metal strips such as aluminum strip or copper strip, and the insulating mounting plate 352 is made of insulating ceramic or engineering plastic or other insulating materials.

[0082] Specifically, the mounting collar 351 is made of metals such as aluminum alloy, copper alloy, or stainless steel, providing good mechanical strength and sealing performance. These materials have excellent corrosion resistance and oxidation resistance, and remain stable at high temperatures. For example, aluminum alloys offer lightweight advantages, reducing overall weight; copper alloys have good thermal conductivity, contributing to even heat distribution; and stainless steel offers higher strength and wear resistance. The most suitable material can be selected based on the specific application scenario.

[0083] The conductive post 353 uses metal strips such as aluminum or copper, which have excellent conductivity. Aluminum and copper are both commonly used conductive materials, with copper having slightly better conductivity than aluminum, but aluminum is lighter. In practical applications, the appropriate material can be selected based on the current rating and heat dissipation requirements of the power element 800. For example, for high-current applications, copper strips with a larger cross-sectional area can be used; while for applications requiring weight reduction, aluminum strips can be used.

[0084] The insulating mounting plate 352 is made of insulating ceramic or engineering plastic, which effectively isolates the conductive post 353 from the mounting collar 351. Insulating ceramic has excellent high-temperature resistance and electrical insulation properties, making it suitable for high-temperature environments; engineering plastic has good processing performance and mechanical strength, and special engineering plastics that are resistant to high temperatures and corrosion can be selected as needed. For example, high-performance engineering plastics such as polyetheretherketone (PEEK) or polyphenylene sulfide (PPS) can be used, which have excellent heat resistance, chemical resistance, and electrical insulation properties.

[0085] In summary, this application effectively solves the material selection problem by rationally choosing the materials for the mounting collar 351, conductive post 353, and insulating mounting plate 352, achieving multifunctional integration of the second sealing flange 350 and improving the overall performance and reliability of the ORC-based thermal management system. This design not only meets the requirements of high temperature, high pressure, and high vacuum environments but also provides an innovative solution for the heat dissipation and electrical connection of the power element 800, possessing significant practical value and technical significance.

[0086] In one embodiment, the ORC thermal management system further includes a gas-liquid separator (not shown) disposed within the working fluid storage tank 600, so that the working fluid in a gas-liquid mixture passing through the condenser 500 can be separated by the gas-liquid separator.

[0087] This technical solution effectively solves the problem of separating the gas-liquid mixture of working fluid within the working fluid storage tank 600 by installing a gas-liquid separator. The working fluid exiting the condenser 500 may not be completely liquefied, but rather in a gas-liquid mixture. The gas-liquid separator separates the gaseous and liquid working fluids, ensuring that the working fluid entering the liquid pump 700 is pure liquid, avoiding potential damage to the liquid pump 700 caused by air bubbles, and also improving the overall system efficiency. This design not only improves system reliability but also extends the service life of the liquid pump 700 and reduces maintenance costs.

[0088] In one embodiment, the ORC thermal management system further includes a first multi-way valve 910, a second multi-way valve 920, and a service pipe 930. The first multi-way valve 910 is used to connect the evaporator 300 and the turbine 400, the second multi-way valve 920 is used to connect the turbine 400 and the condenser 500, and the service pipe 930 connects the first multi-way valve 910 and the second multi-way valve 920.

[0089] This technical solution cleverly solves the system maintenance problem by adding a multi-way valve and a maintenance pipe 930. During normal operation, the working fluid enters the turbine 400 through the first multi-way valve 910 and then enters the condenser 500 through the second multi-way valve 920. When turbine 400 needs maintenance, the two multi-way valves can be adjusted so that the working fluid flows directly from the first multi-way valve 910 to the second multi-way valve 920 through the maintenance pipe 930, bypassing turbine 400. This allows for maintenance of turbine 400 without affecting the overall system operation, greatly improving system maintainability and efficiency.

[0090] In one embodiment, the ORC thermal management system further includes a liquid replenishment and venting valve 610, which is disposed at the upper end of the working fluid storage tank 600 for replenishing the working fluid into the working fluid storage tank 600 through the liquid replenishment and venting valve 610, and for venting excess gas (including but not limited to air and excess gaseous working fluid) from the working fluid storage tank 600 through the liquid replenishment and venting valve 610.

[0091] This configuration allows for the rapid removal of excess gas from the ORC's thermal management system, while also ensuring timely replenishment of the working fluid required by the ORC's thermal management system.

[0092] Furthermore, in one embodiment, the ORC thermal management system also includes a liquid level sensor (not shown) and an alarm (not shown). The liquid level sensor is installed inside the working fluid storage tank 600 and is electrically connected to the alarm. When the liquid level of the working fluid in the working fluid storage tank 600 is lower than a preset level, the liquid level sensor can transmit a signal to the alarm so that the alarm can sound an alarm.

[0093] This configuration makes ORC's thermal management system more intelligent and greatly improves its operational safety.

[0094] It should be noted that the types of working fluids include, but are not limited to, R1234yf, R436a, R433b, R471A, EnasolvFS39, R1233zd(E), R1336mzz(Z), and many others, which will not be listed here.

[0095] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0096] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the scope of protection of this application. Therefore, the patent protection scope of this application should be determined by the appended claims.

[0097] In the description of this application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicating the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0098] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0099] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0100] In this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0101] It should be noted that when an element is referred to as being "fixed to" or "set on" another element, it can be directly on the other element or there may be an intervening element. When an element is considered to be "connected to" another element, it can be directly connected to the other element or there may be an intervening element. The terms "vertical," "horizontal," "upper," "lower," "left," "right," and similar expressions used herein are for illustrative purposes only and do not represent the only possible implementation.

[0102] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein in the specification of this application is for the purpose of describing particular embodiments only and is not intended to be limiting of the application. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

Claims

1. An ORC-based thermal management system, characterized in that, The power element (800) is at least partially immersed in the liquid working medium, the liquid working medium can be gasified by absorbing heat in the evaporator (300) and enter the turbine (400) to drive the turbine (400) to drive the generator (200) to operate and generate electricity, the condenser (500) can liquefy the gaseous working medium by releasing heat and enter the working medium storage tank (600), and the liquid pump (700) can drive the liquid working medium in the working medium storage tank (600) to flow back to the evaporator (300).

2. The ORC-based thermal management system of claim 1, wherein, The evaporator (300) includes a first shell (310), a second shell (320), and a first sealing flange (330), the second shell (320) is provided with a containing cavity with a mounting opening, the power element (800) is mounted in the containing cavity through the mounting opening, and the first shell (310) is detachably mounted at the mounting opening of the first shell (310) and seals the containing cavity through the first sealing flange (330).

3. The ORC-based thermal management system of claim 2, wherein, The evaporator (300) further includes an insulating support (340), and the power element (800) is detachably mounted in the containing cavity of the second shell (320) through the insulating support (340).

4. The ORC-based thermal management system of claim 2, wherein, The evaporator (300) further includes a second sealing flange (350), the second sealing flange (350) is sealingly mounted on the side wall of the second shell (320), and the power element (800) can be electrically connected to external equipment through the second sealing flange (350).

5. The ORC-based thermal management system of claim 4, wherein, The second sealing flange (350) includes a mounting sleeve ring (351), an insulating mounting plate (352), and a conductive column (353), the mounting sleeve ring (351) is sleeved on the outer circumferential side of the insulating mounting plate (352), the second sealing flange (350) can be sealingly mounted on the side wall of the second shell (320) through the mounting sleeve ring (351), a plurality of conductive columns (353) are arranged at intervals, each conductive column (353) is sealingly penetrated at both ends of the insulating mounting plate (352), and the power element (800) can be electrically connected to external equipment through the corresponding conductive column (353).

6. The ORC-based thermal management system of claim 5, wherein, A plurality of conductive columns (353) are arranged in an array on the insulating mounting plate (352).

7. The ORC-based thermal management system of claim 5, wherein, The mounting sleeve ring (351) is detachably mounted on the side wall of the second shell (320) through a fastener (354).

8. The ORC-based thermal management system of claim 1, wherein, A gas-liquid separator is further included, and the gas-liquid separator is arranged in the working medium storage tank (600) to separate the working medium in a gas-liquid mixed form passing through the condenser (500) through the gas-liquid separator.

9. The ORC-based thermal management system of claim 1, wherein, Further comprising a first multi-way valve (910) for connecting the evaporator (300) and the turbine (400), a second multi-way valve (920) for connecting the turbine (400) and the condenser (500), and a maintenance pipe (930) capable of connecting the first multi-way valve (910) and the second multi-way valve (920).

10. The ORC-based thermal management system of claim 1, wherein, Further comprising a liquid supplementing and gas discharging valve (610) disposed at an upper end of the working medium storage tank (600) for supplementing working medium into the working medium storage tank (600) through the liquid supplementing and gas discharging valve (610), and for discharging excess gas in the working medium storage tank (600) through the liquid supplementing and gas discharging valve (610).

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