A heat exchanger
The heat exchanger addresses inefficiencies in compact designs by using mixing means with deflector elements to enhance fluid phase balance and mixing, improving efficiency and compactness in vehicle refrigeration systems.
Patent Information
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- VALEO ELECTRIFICATION
- Filing Date
- 2024-11-22
- Publication Date
- 2026-05-27
AI Technical Summary
Existing heat exchangers face challenges in achieving high heat exchange efficiency while maintaining a compact design, balancing fluid flow phases, and optimizing performance without significant external dimensions or cost impact, particularly in applications like vehicle refrigeration systems.
A heat exchanger design featuring mixing means with deflector elements that redirect fluid flow within distribution passages, enhancing phase balance and homogeneity, comprising a base portion and deflector means projecting from one face to alter fluid direction, with winglets and gaps to optimize fluid mixing and distribution.
The design improves heat exchange efficiency by ensuring homogeneous fluid mixing and increased surface area, thereby enhancing performance and compactness without significant external dimensions or cost increases.
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Abstract
Description
FIELD OF THE INVENTION
[0001] The invention relates to a heat exchanger, in particular the heat exchanger for a motor vehicle.BACKGROUND OF THE INVENTION
[0002] Heat exchange capacity is one indicator for evaluating the performance of heat exchangers and media systems. The heat exchange capacity may vary due to differences in media flow rates in multiple heat exchange channels. The medium may be a gas-liquid two-phase medium in which a gas-phase medium and a liquid-phase medium are mixed. The addition of oil in the medium may also be present. In this case, the difference in the gas-liquid ratio between the gas-phase medium and the liquid-phase medium between the plurality of heat exchange passes may change the heat exchange performance. Thus there is a need to improve the global efficiency of the heat exchanger (e.g. chiller, water- cooled condenser) by improving its heat exchange capability.
[0003] The stacked plate heat exchanger design, such as in chiller or water- cooled condenser is usually suited to transferring heat between medium- and low-pressure fluids. Welded, semi-welded and brazed heat exchangers are used for heat exchange between high-pressure fluids or where a more compact product is required. In place of a pipe passing through a chamber, there are instead two alternating chambers, usually thin in depth, separated at their largest surface by a corrugated metal plate. The plates used in a plate and frame heat exchanger are obtained by one piece pressing of metal plates. Stainless steel is a commonly used metal for the plates because of its ability to withstand high temperatures, its strength, and its corrosion resistance.
[0004] The chiller is a compact heat exchanger using one medium used in vehicle's refrigeration system to cool down the other medium (e.g. water, coolant) used for cooling the batteries or electronics in a hybrid or electric vehicles. Consequently, the chiller must be robust and efficient.
[0005] The know way for improving the efficiency is, for example increasing the heat exchange surface by providing bigger chiller core or by providing multiple passes in said heat exchanger.
[0006] However, these methods are limited by the desired packaging which is especially demanding in modern vehicles. It is desired to provide a heat exchanger which will be suitable for different cooling modes, such as cooling high voltage batteries, cooling of electronic components, cabin cooling, etc. It is thus desired to provide a heat exchanger capable of high heat exchange rate which is well balanced in terms of volume and mass. Finally, it would be desired to provide a homogenous flow through the heat exchanger in an inexpensive way, and without significant impact to its performance or external dimensions.SUMMARY OF THE INVENTION
[0007] The object of the invention is, among others, a heat exchanger for a heat exchange between a first fluid and a second fluid, comprising: a plurality of first heat exchange conduits for the first fluid, and plurality of second heat exchange conduits for the second fluid, the first heat exchange conduits comprising a first axis extending in parallel to first heat exchange conduits, and a first distribution passage, the distribution passage comprising a distribution axis extending in perpendicular to the first axis to intersect the plurality of first heat exchange conduits along the distribution axis, so that the first heat exchange conduits are in fluidal communication with the distribution passage, wherein the heat exchanger further comprises at least one mixing means arranged at least at distribution passage, wherein the mixing means comprises a base portion comprising a first face and a second face opposite to the first face, the faces being being substantially parallel to the first axis, and deflector means protruding directly from the base portion, wherein the deflector means is arranged exclusively on the side of the second face.
[0008] Advantageously, the mixing means is configured to at least partially deflect the intended first fluid flow direction in the first distribution passage.
[0009] Advantageously, the mixing means comprise an outer aperture and an inner aperture, wherein the deflector means are located between the outline delimited by the outer aperture and the inner aperture.
[0010] Advantageously, the deflector means are arranged at an angle with respect to the base portion, wherein said deflector means project from the outer aperture towards the distribution axis.
[0011] Advantageously, at least part of the deflector means project into the distribution channel.
[0012] Advantageously, the deflector means comprise a first winglet and at least one second winglet, wherein said winglets are arranged radially with respect to the outer aperture and / or the inner aperture.
[0013] Advantageously, the deflector means comprises at least one gap arranged in-between neighboring winglets, wherein said gap extends from the inner aperture towards the base portion.
[0014] Advantageously, the deflector means have substantially trapezoidal shape.
[0015] Advantageously, the deflector means have substantially triangular -shape.
[0016] Advantageously, the heat exchanger further comprises a plurality of plates stacked together in a first stacking direction being perpendicular to the first axis, wherein said plates constitute conduits, wherein the plurality of plates comprises a first end plate comprising at least one inlet for the first fluid, and a second end plate, the first end plate and the second end plate being located on both ends of the plurality of plates, in relation to a stacking direction of said plurality plates.
[0017] Advantageously, at least one mixing means is arranged between the inlet and the plurality of plates.
[0018] Advantageously, at least one mixing means is arranged within the plurality of plates.
[0019] Advantageously, at least one mixing means is made integral with the plurality of plates.
[0020] Advantageously, at least one mixing means is made integral with the first end plate.BRIEF DESCRITPTION OF DRAWINGS
[0021] Examples of the invention will be apparent from and described in detail with reference to the accompanying drawings, in which: Fig.1 shows a perspective view of the heat exchanger. Fig. 2 shows a partial cross- section of the heat exchanger with possible arrangements of a mixing means. Fig. 3 shows the standalone mixing means viewed from its first face. Fig. 4 shows the standalone mixing means viewed from its second face. Fig. 5 shows a perspective view of the standalone mixing means. DETAILED DESCRIPTION OF THE INVENTION
[0022] The subject- matter of the invention relates to a heat exchanger 1. The heat exchanger 1 may be configured for a heat exchange between a first fluid and a second fluid. The first fluid may be, for example, a refrigerant, and the second fluid may be a different fluid, for example, a coolant.
[0023] The heat exchanger may comprise a plurality of first heat exchange conduits 111 for the first fluid. It should be noted that the first fluid may be a fluid comprising two or more phases. For example, the first fluid may be a mixture of oil, liquid and gas.
[0024] The heat exchanger 1 may further comprise a plurality of second heat exchange conduits 222 for the second fluid. The second fluid may be, for example, a coolant. The second heat exchange conduits 222 may be arranged alternately with the first heat exchange conduits 111 so that the heat exchange between the first fluid is maximized due to increase of the heat exchange surface vis-à-vis two fluids.
[0025] The term first heat exchange conduits 111 and second heat exchange conduits 222 refer in general to the means of fluid-tight fluid transfer. In order to maximize the heat exchange area, it is preferable that the conduits 111, 222 have big heat exchange area. Thus it is preferred that the conduits 111, 222 have e.g. rectangular shape. The example of such configuration may be present, for example in a plate type heat exchanger for a motor vehicle. Most popular examples of such heat exchangers 1 may be, for example, a chiller or a water- cooled condenser. However, other types of the heat exchangers 1 are also envisaged. For the sake of clarity and conciseness, the subject matter of the present invention is described based on the chiller characteristics and such characteristics are present in figures.
[0026] The first heat exchange conduits 111 (or simply: first conduits 111) may comprise a first axis Y1 extending in parallel to first heat exchange conduits 111. In other words, each first conduit 111 may comprises a first axis Y1 along which the first fluid is intended to flow. As the plurality of first conduits 111 comprise multiple first axes Y1 which are parallel, one can simplify the description and just mention one first axis Y1. For the sake of clarity the first axis Y1 for all first conduits may be regarded as the first axis Y1 of the first conduit 111 which is located in the middle with respect to the other first conduits 111. The first axis Y1 may also apply to second conduits 222 as they are parallel to first conduits 111.
[0027] To be more precise, the first conduits may comprise a general plane of extension P1- or simply, the general plane P1. The general plane P1 is shown in Fig 1. The first axis Y1 may be parallel to the general plane P1. Naturally, the second conduits 222 may also be parallel to the general plane P1.
[0028] The heat exchanger 1 may further comprise a first distribution passage 101 (or simply: a first passage 101). The first passage 101 is configured to distribute the first flow into the first conduits 111. In other words, the first passage 101 plays role of manifold for the heat exchanger 1. It receives the first fluid from the loop and it distributes it to the first passes 111 so that heat exchange takes place.
[0029] Naturally, a first passage 101 is not the only one possible in the heat exchanger 1. The heat exchanger 1 may further comprises a second passage 102 for the first fluid. The first passage 101 and the second passage 102 are fluidly connected by the first passes 111. Therefore, the first passage 101 may be regarded as inlet manifold, the second passage may be regarded as outlet manifold, and in-between these manifolds the first passes 111 may extend. Similarly, the heat exchanger 1 may comprise a third passage (not shown) for the second fluid, and a fourth passage (not shown) for the second fluid. In this case the third passage may be regarded as the inlet manifold for the second fluid, whereas the fourth passage may be regarded as the outlet manifold for the second fluid. The third passage and the fourth passage may be fluidly connected by the second passes 222 which are apparent in Fig. 2.
[0030] The first the distribution passage 101 may comprise a distribution axis X1. In case of the heat exchanger 1 is a plate type heat exchanger, the distribution passage is formed by the openings in consecutive plates so that the manifold is created. These openings forming the distribution passage 101 may comprise the distribution axis X1 which may extend in perpendicular to the first axis Y1, so X1 is normal to the direction of the conduits 111, 222. The first axis X1 may intersect the plurality of first heat exchange conduits 111 along the distribution axis X1, so that the first heat exchange conduits 111 are in fluidal communication with the distribution passage 101. This allows the distribution of the first fluid into the first conduits. One should bear in mind that the analogical relationship applies also for the second conduit 222, i.e. it also comprises the distribution axis but it is for enabling second fluid into the second conduits 222.
[0031] Consequently, the distribution axis X1 may extend in perpendicular to the general plane P1 as well, so X1 is normal to the direction of the conduits 111, 222.
[0032] The heat exchanger 1 further comprises at least one mixing means 500. The mixing means 500 allow balancing the phases in the distribution passage 101 and consequently, in the first conduits 111. This enhances the heat exchange between the first fluid having two or more phases with the second fluid. Although it is preferred that the mixing means 500 are arranged at the beginning of the distribution passage 101 (i.e. at the portion of the inlet manifold in which the first fluid is intended to flow first), other locations of the mixing means 500 are also envisaged and discussed in further paragraphs.
[0033] The mixing means 500 may comprise a base portion 505. The base portion 505 may be regarded as the portion which is arranged in the heat exchanger 1 in parallel to the general plane P1. This means that the base portion 505 can be made as unitary with the sub-component of the heat exchanger 1 or that it can be a standalone component fixed to said sub-component. Notwithstanding the form of the base portion 505, one can recognize that the base portion 505 may comprise a first face 505A and a second face 505B opposite to the first face 505A. There is no significant structural difference between the first face 505A and the second face 505B - they are distinguished so that they can be regarded as reference points throughout the description.
[0034] Naturally, the faces 505A, 505B are substantially parallel to the general plane P1.
[0035] The term substantially parallel means that the faces 505A, 505B are arranged at the null angle with respect to the general plane P1. The deviations from null angle are also envisaged due to tolerances or intentional arrangement. Thus, it should be noted that the angle between any of the faces 505A, 505B and the general plane may be null i.e. 0 degrees, or any of the faces 505A, 505B may be arranged at a non-null angle with respect to the general plane P1, for example 1-9 degrees.
[0036] Also, it may be also envisaged that the second face 505B is not parallel with respect to the first face 505A (i.e. the first face 505A is slanted with respect to the second face 505B). In this case it is preferable that at least one of the first face 505A or the second face 505B is parallel to the general plane P1. Such configuration may be in some cases beneficial in terms of increasing robustness of the heat exchanger 1 or optimizing performance thereof.
[0037] The mixing means 500 may further comprise deflector means 555. The deflector means 555 may actively change the intended first fluid flow direction, so that the two or more phases of the first fluid are mixed with each other. In other words, the deflector means 555 increase homogeneity of the first fluid in terms of phase composition.
[0038] The deflector means 555 may be protruding directly from the base portion 505. It means that it is preferred that there is continuity of material between the base portion 505 and the deflector means 555 (i.e. deflector means 555 are made integral with base portion 505. It should be noted that the base portion 505 surrounds the deflector means 555. The deflector means 555 are inclined with respect to the base portion 505. Consequently, the deflector means 555 are angled with respect to the general plane P1 and / or the first axis Y1 as well.
[0039] It is significant that the deflector means 555 are inclined only to the one side of the mixing means 500. Thus the deflector means 555 is arranged exclusively on the side of the second face 505B. It means that the deflector means 555 protrude in a direction away from the first face 505A. The deflector means 555 thus never intersect the plane formed by the first face 505A of the base portion 505. They only slightly intersect the second face 505B at an inflection point R1, whereas the inflection point R1 is part of the deflector means 555. The distance between the first face 505A and the second face 505B may be regarded as the thickness of the base portion 505. The inflection point R1 of the deflector means 555 may be located in the thickness area of the base portion 505, i.e. between the first face 505A and the second face 505B. The inflection point R1 sets the initial angle in which the deflector means 555 may protrude in a direction that is at an angle both with the first axis Y1 and the distribution axis X1, as well as between the general plane P1 and the distribution axis X1.
[0040] This way at least part of the deflector means 555 project into the distribution channel 101.
[0041] However, it is envisaged that the deflector means 555 may comprise another inclinations past the inflection point R1 (i.e. away from the base portion 505).
[0042] The mixing means 500 means may be arranged directly at the distribution passage 101 so that it is configured to at least partially deflect the intended first fluid flow direction in the first distribution passage 101. This enables well-mixed first fluid to enter the distribution passage and consequently, first passes 111.
[0043] The mixing means 500 may comprise an outer aperture 506 and an inner aperture 507. The outer aperture 506 may be regarded as the frontier between the base portion 505 and the deflector means 555. In this case , the outer aperture 506 is formed on the base portion 505. The outer aperture 506 and the inner aperture 507 allow the first fluid flow through the mixing means 500. The outer aperture 506 allows the first fluid to flow past the level of first face 505A and the second face 505B of the base portion 505, whereas the inner aperture 507 enables fluid flow past the level of the deflector means 555. As the result of this, it is apparent that the deflector means 555 are located between the outline delimited by the outer aperture 506 and the inner aperture 507. It is preferable that the shape of the inner aperture 507 and the outer aperture 506 is circular, yet other shapes of the apertures 506, 507 are also envisaged. Further, as the deflector means 555 are arranged at an angle with respect to the base portion 505, said deflector means 555 project from the outer aperture 506 towards the distribution axis X1.
[0044] The deflector means 555 have functional structure as explained in previous paragraphs. From the structural point of view, the deflector means may comprise a first winglet 555A and at least one second winglet 555B, 555C, 555D, 555E, 555F. It should be noted that two winglets is minimum to provide first fluid flow between the apertures 506, 507. Otherwise, the deflector means 555 cannot be considered as mixing means 500.
[0045] For the sake of coherence, the further paragraphs refer to total of six winglets, so one first winglet 555A and five second winglets 555B, 555C, 555D, 555E, 555F. One should bear in mind that different number of second winglets 555B, 555C, 555D, 555E, 555F is also envisaged.
[0046] The winglets 555A, 555B, 555C, 555D, 555E, 555F actively deflect the first fluid, whereas the individual winglets 555B, 555C, 555D, 555E, 555F protrude from the base portion 505. Ideally, said winglets 555A, 555B, 555C, 555D, 555E, 555F are arranged radially with respect to the outer aperture 506 and / or the inner aperture 507, depending on which reference point the skilled person selects.
[0047] The deflector means 555 comprises at least one gap 556 arranged in-between neighboring winglets 555A, 555B, 555C, 555D, 555E, 555F, wherein said gap 556 extends from the inner aperture 507 towards the base portion 505. The gap 556 allows the first fluid flow between the inner aperture 507, outer aperture 506, and neighboring winglets 555A, 555B, 555C, 555D, 555E, 555F.
[0048] The winglets 555A, 555B, 555C, 555D, 555E, 555F may have substantially trapezoidal shape. The term substantially indicates that that the shape of the individual winglet 555A, 555B, 555C, 555D, 555E, 555F may be associated with the trapezoid. Alternatively, the deflector means 555 have substantially triangular -shape. In particular the winglets 555A, 555B, 555C, 555D, 555E, 555F may comprise substantially triangular -shape.
[0049] Next paragraphs aim to describe potential locations of the mixing means 500 in the heat exchanger 1. One should bear in mind that the examples giving throughout the description are non-limiting.
[0050] In general, the mixing means 500 may be arranged at the entrance of the distribution channel 101. The inner aperture 507 of the mixing means 500 may be intersected by the distribution axis X1 to allow perfect alignment of the deflector means 555 in the heat exchanger 1.
[0051] The heat exchanger 1 may further comprises a plurality of plates 900 stacked together in a first stacking direction, as shown in Fig. 1. The plates 900 may be arranged in parallel to the general plane P1, whereas the first stacking direction may be parallel to distribution axis X1. From the structural point of view, it is the plates 900 that may constitute conduits 111, 222. For example, the pair of plates 900 are arranged together to form single first conduit 111. Next, another plate 900 is fixed to said pair and the second conduit is formed. This way, each plate 900 may be neighboring with the first conduit 111 and the second conduit 222. In other words, individual plate 900 may form first conduit and the second conduit 222 by providing fluidal insulation between them (or rather the first fluid and the second fluid flowing in neighboring conduits 111,222. The mixing means may be fixed (e.g. by brazing) to one of the plates 900. Alternatively, the mixing means 500 may be made integral with any of the plates 900.
[0052] The plurality of plates 900 may comprise a first end plate 901 comprising at least one inlet 901A for the first fluid. The end plate 901 may be the same plate as other plates 900, or it may have different parameters (e.g. thickness, etc.), the location thereof being crucial for calling it the first end plate 901. Similarly, the plurality of plates 900 may comprise a second end plate 902. The first end plate 901 and the second end plate 902 may be located on both ends of the plurality of plates 900, in relation to a stacking direction of said plurality plates 900. In other words, the end plates 901, 902 terminate the stack of plates 900 in a stacking direction. The inlet 901A may be an opening which allows the first fluid into the heat exchanger. Naturally, the heat exchanger may also comprise an outlet 901B for the first fluid, as well as an inlet 902A for the second fluid and an outlet 902B for the second fluid. The inlet 901A and the outlet 901B for the first fluid may be fluidly connected to a first block 801A, and a second block 801B, respectively, whereas an inlet 902A and outlet 902B for the second fluid may be fluidly connected to a first nozzle 802A, and a second nozzle 802B, respectively.
[0053] At least one mixing means 500 may arranged between the inlet 901A and the plurality of plates 900. This allows promoting the mixing of the first fluid as soon as the first fluid enters the heat exchanger 1. Similarly, at least one mixing means 500 may be made integral with the first end plate 901 to achieve similar effect.
[0054] Additionally, or alternatively, at least one mixing means 500 may be arranged within the plurality of plates 900. In other words, the mixing means may be located in the distribution manifold 101, between the end plates 901, 902.
[0055] Other variations to the disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed invention, from a study of drawings, the disclosure, and the appended claims. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to the advantage.
Claims
1. A heat exchanger (1) for a heat exchange between a first fluid and a second fluid, comprising: a plurality of first heat exchange conduits (111) for the first fluid, and plurality of second heat exchange conduits (222) for the second fluid, the first heat exchange conduits (111) comprising a general plane of extension (P1), and a first distribution passage (101), the distribution passage (101) comprising a distribution axis (X1) extending in perpendicular to the general plane of extension (P1) to intersect the plurality of first heat exchange conduits (111) along the distribution axis (X1), so that the first heat exchange conduits (111) are in fluidal communication with the distribution passage (101), wherein the heat exchanger (1) further comprises at least one mixing means (500) arranged at least at the distribution passage (101), wherein the mixing means (500) comprises a base portion (505) comprising a first face (505A) and a second face (505B) opposite to the first face (505A), the faces being (505A, 505B) being substantially parallel to the general plane of extension (P1), and deflector means (555) protruding directly from the base portion (505) , wherein the deflector means (555) is arranged exclusively on the side of the second face (505B).
2. The heat exchanger (1) according to claim 1, wherein the mixing means (500) is configured to at least partially deflect the intended first fluid flow direction in the first distribution passage (101).
3. The heat exchanger (1) according to any of the preceding claims, wherein the mixing means (500) comprise an outer aperture (506) and an inner aperture (507), wherein the deflector means (555) are located between the outline delimited by the outer aperture (506) and the inner aperture (507).
4. The heat exchanger (1) according to claim 3, wherein the deflector means (555) are arranged at an angle with respect to the base portion (505), wherein said deflector means (555) project from the outer aperture (506) towards the distribution axis (X1).
5. The heat exchanger (1) according to any of the preceding claims, wherein at least part of the deflector means (555) project into the distribution channel (101).
6. The heat exchanger (1) according to claims 3-5, wherein the deflector means (555) comprise a first winglet (555A) and at least one second winglet (555B, 555C, 555D, 555E, 555F), wherein said winglets (555A, 555B, 555C, 555D, 555E, 555F) are arranged radially with respect to the outer aperture (506) and / or the inner aperture (507).
7. The heat exchanger (1) according to claim 6, wherein the deflector means (555) comprises at least one gap (556) arranged in-between neighboring winglets (555A, 555B, 555C, 555D, 555E, 555F), wherein said gap (556) extends from the inner aperture (507) towards the base portion (505).
8. The heat exchanger (1) according to any of the preceding claims, wherein the deflector means (555) have substantially trapezoidal shape.
9. The heat exchanger (1) according to any of claims 1-7, wherein the deflector means (555) have substantially triangular shape.
10. The heat exchanger (1) according to any of the preceding claims, wherein the heat exchanger (1) further comprises a plurality of plates (900) stacked together in a first stacking direction being perpendicular to general plane of extension (P1), wherein said plates (900) constitute conduits (111, 222), wherein the plurality of plates (900) comprises a first end plate (901) comprising at least one inlet (901A) for the first fluid, and a second end plate (902), the first end plate (901) and the second end plate (902) being located on both ends of the plurality of plates (900), in relation to a stacking direction of said plurality plates (900).
11. The heat exchanger (1) according to any of the preceding claims, wherein at least one mixing means (500) is arranged between the inlet (901A) and the plurality of plates (900).
12. The heat exchanger (1) according to any of claims 10 or 11, wherein at least one mixing means (500) is arranged within the plurality of plates (900).
13. The heat exchanger (1) according to any of claims 10-12, wherein at least one mixing means (500) is made integral with the plurality of plates (900).
14. The heat exchanger (1) according to any of claims 10-13, wherein at least one mixing means (500) is made integral with the first end plate (901).