Condenser and compressor integrated structure for integrated thermal management system
Patent Information
- Application Number
- CN202522535469.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-11-28
- Publication Date
- 2026-09-25
- Estimated Expiration
- 2035-11-28
AI Technical Summary
这种集成式热管理系统虽然在一定程度上提升了集成度，但是，其在结构上仍存在显著缺陷：（1）连接冗余导致泄漏风险高，管路与接头的大量使用，使系统接口数量倍增，尤其对于R290等可燃冷媒，微小泄漏即可能引发安全隐患，而传统分布式结构的安全性无法满足R290冷媒的要求；（2）集成效率低下，分散式管路连接使部件布局分散，系统整体体积偏大，占用车辆有限安装空间，同时增加了装配工序与成本；（3）管路连接存在流阻与换热损失，导致压缩机输出的能量无法高效传递至LCC板式换热器，能量传输损耗大，热管理效率受限；（4）低温适应性差，独立管路的热损失加剧了低温环境下的能量耗散，使得系统制热量不足，压缩机易因负荷过高出现过热保护，难以在-30℃等极端低温工况下稳定运行
这种冷凝器与压缩机一体化结构适用于集成式热管理系统中，其将板式换热器的冷媒侧端面与压缩机的高压盖面对面贴合并在相互连接固定在一起，并将压缩机的排气口与冷媒侧端面上的气态冷媒入口相对准连通，由此可以使压缩机排出的高温高压冷媒直接进入板式换热器中进行换热，取消传统结构中二者之间的连接管路，这一方面大幅减少了冗余管路与接头的数量，从连接源头有效消除R290等可燃冷媒的泄漏风险，提升系统安全性，另一方面缩短了冷媒传输路径，减少流阻造成的能量损耗与热损失，提升热管理系统的换热效率，低温适应性强，同时能够使得集成式热管理系统的整体结构更为紧凑，减少其占用的车辆安装空间，适配新能源汽车紧凑的安装环境。
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Abstract
Description
Technical Field
[0001] This utility model relates to vehicle thermal management technology, specifically to an integrated structure of condenser and compressor for an integrated thermal management system. Background Technology
[0002] With the rapid development of new energy vehicles, automotive air conditioning systems have gradually expanded from meeting only cooling needs to meeting diverse thermal management requirements, including cooling, heating, battery thermal management, and small-scale refrigeration needs. Furthermore, they often need to handle the cooling and heating needs of different units simultaneously. This highly complex requirement renders traditional distributed air conditioning structures inadequate, as their dispersed components and complex piping connections result in low system efficiency and poor reliability.
[0003] Currently, integrated thermal management systems are increasingly being applied to new energy vehicles. These systems utilize a refrigerant system and an external water system for secondary heat exchange to achieve thermal management goals. A typical integrated thermal management system mounts four main components—compressor, condenser, expansion valve, and evaporator—on a single base plate. Most systems use LCC plate heat exchangers as condensers and Chiiller plate heat exchangers as evaporators. Both the LCC and Chiiller plate heat exchangers provide cold and heat sources to external thermal units via the water side. The external thermal units connect to the heat or cold source according to a control strategy to achieve the desired thermal piping goals. For example: [Reference] Figure 1An existing integrated thermal management system includes a compressor 01, a condenser 02, a first expansion valve 03, an integrator 04, a second expansion valve 05, an evaporator 06, and multiple temperature and pressure sensors 07. The compressor 01, condenser 02, first expansion valve 03, integrator 04, second expansion valve 05, and evaporator 06 are connected sequentially through pipes 010 to form a circulation loop. Each temperature and pressure sensor 07 is installed on a corresponding pipe 010. The condenser 02 uses an LCC plate heat exchanger, and the evaporator 06 uses a chiiller plate heat exchanger. During operation, the high-temperature and high-pressure refrigerant discharged from the exhaust port 011 of the compressor 01 enters the condenser 02 through the corresponding pipeline 010 and the gaseous refrigerant inlet 021. After condensation, the resulting medium-temperature liquid refrigerant first passes through the first expansion valve 03 for primary throttling, then through the integrator 5 and the corresponding pipeline 010 to enter the second expansion valve 6 for secondary throttling, and then through the corresponding pipeline 010 to enter the liquid refrigerant inlet 061 of the evaporator 6. After absorbing heat through evaporation and becoming a superheated gaseous state, it exits from the gaseous refrigerant outlet 062, and finally enters the suction port 012 of the compressor 01 through the corresponding pipeline 010, thus realizing the entire refrigerant cycle. Although this integrated thermal management system improves the integration to a certain extent, it still has significant structural defects: (1) Redundant connections lead to high leakage risk. The extensive use of pipes and joints increases the number of system interfaces. Especially for flammable refrigerants such as R290, even a small leak can cause safety hazards. The safety of traditional distributed structures cannot meet the requirements of R290 refrigerant. (2) Low integration efficiency. Distributed pipe connections result in dispersed component layout, larger overall system volume, occupying limited vehicle installation space, and increasing assembly procedures and costs. (3) Pipe connections have flow resistance and heat exchange losses, which prevent the energy output of the compressor from being efficiently transferred to the LCC plate heat exchanger. The energy transmission loss is large, and the thermal management efficiency is limited. (4) Poor low temperature adaptability. The heat loss of independent pipes exacerbates the energy dissipation in low temperature environments, resulting in insufficient heating capacity of the system. The compressor is prone to overheating protection due to excessive load, making it difficult to operate stably under extreme low temperature conditions such as -30℃. Utility Model Content
[0004] The technical problem this invention aims to solve is to provide an integrated condenser and compressor structure for an integrated thermal management system. This integrated condenser and compressor structure not only makes the overall structure of the integrated thermal management system more compact, reducing its vehicle installation space, but also reduces energy transmission loss and effectively eliminates the risk of refrigerant leakage. The technical solution adopted is as follows: An integrated condenser and compressor structure for an integrated thermal management system includes a condenser and a compressor. The condenser is a plate heat exchanger, and a gaseous refrigerant inlet is provided on the refrigerant-side end face of the plate heat exchanger. The compressor is characterized by having a high-pressure cover installed on it, located near the refrigerant-side end face of the plate heat exchanger. The side of the high-pressure cover near the plate heat exchanger is in surface contact with and connected to the refrigerant side of the plate heat exchanger. The compressor's exhaust port is located on the high-pressure cover and is aligned and connected to the gaseous refrigerant inlet.
[0005] This integrated condenser and compressor structure is suitable for integrated thermal management systems. It uses a plate heat exchanger as the condenser, with the refrigerant side of the plate heat exchanger and the high-pressure cover of the compressor face-to-face and connected together. The compressor's exhaust port is aligned and connected to the gaseous refrigerant inlet on the refrigerant side. This allows the high-temperature, high-pressure refrigerant discharged from the compressor to directly enter the plate heat exchanger for heat exchange, eliminating the connecting pipes between the two in traditional structures. This significantly reduces the number of redundant pipes and joints, effectively eliminating the risk of leakage of flammable refrigerants such as R290 from the connection source, improving system safety. On the other hand, it shortens the refrigerant transmission path, reduces energy and heat loss caused by flow resistance, improves the heat exchange efficiency of the integrated thermal management system, has strong low-temperature adaptability, and allows for a more compact overall system structure, reducing the vehicle installation space it occupies and adapting to the compact installation environment of new energy vehicles.
[0006] As a preferred embodiment of this utility model, the condenser adopts an LCC plate heat exchanger.
[0007] As a preferred embodiment of this utility model, the compressor is a gas-injection enthalpy-increasing compressor. The gas-injection enthalpy-increasing compressor provides a gas-injection enthalpy-increasing circuit for the integrated thermal management system in low-temperature mode. This circuit uses an integrated flash evaporation method to achieve heat exchange for gas-injection enthalpy enhancement, enabling the integrated thermal management system to significantly improve heating capacity and reduce compressor exhaust temperature, allowing for normal heating at temperatures as low as -30°C. This solves the problems of insufficient low-temperature heating capacity and compressor overheating in ordinary integrated systems.
[0008] As a preferred embodiment of this utility model, the side of the high-pressure cover near the plate heat exchanger is in surface contact with the refrigerant side end face of the plate heat exchanger and is connected to each other by welding.
[0009] As a further preferred embodiment of this utility model, the side of the high-pressure cover near the plate heat exchanger is connected to the refrigerant side of the plate heat exchanger by brazing. Using brazing to connect the high-pressure cover and the plate heat exchanger into a single unit ensures a more stable connection between them.
[0010] In another preferred embodiment of this utility model, the refrigerant side of the plate heat exchanger is provided with an end plate. This end plate and the high-pressure cover are in surface contact and connected to each other by molding to form a molded assembly. The molded assembly and the heat exchange plate of the plate heat exchanger are connected to each other by brazing. First, the high-pressure cover and the end plate on the refrigerant side of the plate heat exchanger are connected to each other by molding to form a molded assembly. Then, the molded assembly and the heat exchange plate of the plate heat exchanger are connected to each other by brazing to form an integral structure, which makes the overall structure more compact and the connection more stable.
[0011] As a further preferred embodiment of this utility model, the end plate and the high-pressure cover are formed by hot forging to form the molded component.
[0012] Compared with the prior art, this utility model has the following advantages: This integrated condenser and compressor structure is suitable for integrated thermal management systems. It connects and fixes the refrigerant side of the plate heat exchanger to the high-pressure cover of the compressor face-to-face, and aligns and connects the compressor's exhaust port with the gaseous refrigerant inlet on the refrigerant side. This allows the high-temperature, high-pressure refrigerant discharged from the compressor to directly enter the plate heat exchanger for heat exchange, eliminating the connecting pipes between the two in traditional structures. This significantly reduces the number of redundant pipes and joints, effectively eliminating the risk of leakage of flammable refrigerants such as R290 from the connection source, improving system safety. On the other hand, it shortens the refrigerant transmission path, reduces energy and heat loss caused by flow resistance, improves the heat exchange efficiency of the thermal management system, and has strong low-temperature adaptability. At the same time, it makes the overall structure of the integrated thermal management system more compact, reducing the vehicle installation space it occupies and adapting to the compact installation environment of new energy vehicles. Attached Figure Description
[0013] Figure 1 This is a schematic diagram of the structure of an integrated thermal management system in the prior art.
[0014] Figure 2 This is a structural schematic diagram of a preferred embodiment of the present invention.
[0015] Figure 3 This is a schematic diagram of the structure of a preferred embodiment of the present invention, Example 2. Detailed Implementation
[0016] Example 1, as Figure 2As shown, this integrated condenser and compressor structure for an integrated thermal management system includes a compressor 1 and a condenser. The condenser adopts an LCC plate heat exchanger 2, and a gaseous refrigerant inlet 201 is provided on the refrigerant side end plate 21 of the LCC plate heat exchanger 2. A high-pressure cover 11 is installed on the compressor 1. The high-pressure cover 11 is located on the side of the LCC plate heat exchanger 2 close to the refrigerant side end plate 21. The side of the high-pressure cover 11 close to the LCC plate heat exchanger 2 is in surface contact with the refrigerant side of the LCC plate heat exchanger 2 and is connected and fixed together. The exhaust port 101 of the compressor 1 is opened on the high-pressure cover 11 and is aligned and connected to the gaseous refrigerant inlet 201.
[0017] In this embodiment, compressor 1 is a gas-injection enthalpy-increasing compressor. The gas-injection enthalpy-increasing compressor provides a gas-injection enthalpy-increasing circuit for the integrated thermal management system in low-temperature mode. The gas-injection enthalpy-increasing circuit uses an integrated flash evaporation method to achieve heat exchange for gas-injection enthalpy increase, enabling the integrated thermal management system to significantly improve heating capacity and reduce the exhaust temperature of compressor 1, allowing for normal heating at temperatures as low as -30°C. This solves the problems of insufficient low-temperature heating capacity and overheating of compressor 1 in ordinary integrated systems.
[0018] In this embodiment, the side of the high-pressure cover 11 near the LCC plate heat exchanger 2 is in surface contact with the refrigerant side end face 21 of the LCC plate heat exchanger 2 and is connected to each other by brazing. Using brazing to connect the high-pressure cover 11 and the LCC plate heat exchanger 2 into a whole makes the connection between the two more stable.
[0019] Example 2, reference Figure 3 While all other parts are the same as in Embodiment 1, the difference lies in the following: In this embodiment, the refrigerant side of the LCC plate heat exchanger 2 is provided with an end plate 22. This end plate 22 and the high-pressure cover 11 are in surface contact and connected to each other by hot forging to form a molded assembly 20. The molded assembly 20 and the heat exchange plates of the LCC plate heat exchanger 2 are connected to each other by brazing. First, the high-pressure cover 11 and the end plate 22 on the refrigerant side of the LCC plate heat exchanger 2 are connected to each other by hot forging to form a molded assembly 20. Then, the molded assembly 20 and the heat exchange plates of the LCC plate heat exchanger 2 are connected to each other by brazing to form an integral structure. This makes the overall structure more compact and the connection more stable.
[0020] Furthermore, it should be noted that the names of the various parts of the specific embodiments described in this specification may differ. All equivalent or simple variations made to the structure, features, and principles of this utility model patent are included within the protection scope of this utility model patent. Those skilled in the art to which this utility model pertains may make various modifications or additions to the described specific embodiments or use similar methods to replace them, as long as they do not deviate from the structure of this utility model or exceed the scope defined by the claims, all of which should fall within the protection scope of this utility model.
Claims
1. An integrated condenser and compressor structure for an integrated thermal management system, comprising a condenser and a compressor, wherein the condenser employs a plate heat exchanger, and a gaseous refrigerant inlet is provided on the refrigerant-side end face of the plate heat exchanger, characterized in that: The compressor is equipped with a high-pressure cover, which is located on the side of the plate heat exchanger near the refrigerant side. The side of the high-pressure cover near the plate heat exchanger is in surface contact with the refrigerant side of the plate heat exchanger and is connected and fixed together. The exhaust port of the compressor is opened on the high-pressure cover and is aligned and connected to the gaseous refrigerant inlet.
2. The integrated condenser and compressor structure for an integrated thermal management system according to claim 1, characterized in that: The condenser uses an LCC plate heat exchanger.
3. The integrated condenser and compressor structure for an integrated thermal management system according to claim 1, characterized in that: The compressor is a gas-injection enthalpy-increasing compressor.
4. The integrated condenser and compressor structure for an integrated thermal management system according to any one of claims 1-3, characterized in that: The high-pressure cover is connected to the refrigerant side of the plate heat exchanger by welding.
5. The integrated condenser and compressor structure for an integrated thermal management system according to claim 4, characterized in that: The high-pressure cover is connected to the refrigerant side of the plate heat exchanger by brazing.
6. The integrated condenser and compressor structure for an integrated thermal management system according to any one of claims 1-3, characterized in that: The plate heat exchanger has an end plate on the refrigerant side. The end plate and the high-pressure cover are connected to each other by molding to form a molded assembly. The molded assembly and the heat exchange plate of the plate heat exchanger are connected to each other by brazing.
7. The integrated condenser and compressor structure for an integrated thermal management system according to claim 6, characterized in that: The end plate and the high-pressure cover are formed by hot forging.