Integrated thermal management device based on 3D printing technology, vehicle thermal management system, and vehicle

Abstract

An integrated thermal management device based on 3D printing technology, a vehicle thermal management system, and a vehicle. The thermal management device comprises a heat exchanger main body (1). The heat exchanger main body (1) is an integrally formed component, and comprises a water-cooled condenser unit (11), a cooler unit (12), and a valve-island liquid distribution unit (13). The valve-island liquid distribution unit (13) is located between the water-cooled condenser unit (11) and the cooler unit (12). The water-cooled condenser unit (11) can communicate with a discharge port of a compressor (20) or with the cooler unit (12) by means of the valve-island liquid distribution unit (13). The cooler unit (12) is configured to communicate with a suction port of the compressor (20).

Description

Integrated thermal management device based on 3D printing technology, vehicle thermal management system and vehicle

[0001] This application claims priority to Chinese Patent Application No. 202411220486.X, filed with the Chinese Patent Office on September 2, 2024, the entire contents of which are incorporated herein by reference. Technical Field

[0002] This application relates to the field of vehicle thermal management technology, such as an integrated thermal management device, thermal management system and vehicle based on 3D printing technology. Background Technology

[0003] The automotive thermal management system mainly uses heat dissipation, heating, and insulation to regulate the car cabin environment and the working environment of components, so that different components can work normally at the appropriate temperature, thereby ensuring the comfort and functional safety of the car.

[0004] Conventional automotive thermal management systems typically consist of heat exchangers comprising multiple components, each requiring individual fabrication before being assembled onto a compressor. This assembly method results in a bulky thermal management system that occupies significant installation space, hindering efficient use of vehicle space. Furthermore, the assembly of multiple components introduces tolerances, potentially leading to substandard precision after assembly, increased assembly difficulty, and higher production costs. Summary of the Invention

[0005] This application provides an integrated thermal management device, a vehicle thermal management system, and a vehicle based on 3D printing technology, which can reduce the size of the integrated thermal management device and the vehicle thermal management system based on 3D printing technology, reduce the required installation space, and reduce the assembly difficulty.

[0006] The following technical solution is adopted in this application:

[0007] In a first aspect, an integrated thermal management device based on 3D printing technology is provided, including a heat exchanger body, wherein the heat exchanger body is an integrally molded component;

[0008] The heat exchanger body includes an integrally formed water-cooled condenser unit, a cooler unit, and a valve island liquid distribution unit. The valve island liquid distribution unit is located between the water-cooled condenser unit and the cooler unit. The water-cooled condenser unit can be connected to the compressor's exhaust port or the cooler unit through the valve island liquid distribution unit. The cooler unit is configured to be connected to the compressor's suction port.

[0009] In some embodiments, the water-cooled condenser unit includes an integrally formed water-cooled condenser body and a water-cooled condenser liquid distribution section disposed at a first end of the water-cooled condenser body. The water-cooled condenser liquid distribution section is connected to the valve island liquid distribution unit, and a first inlet and a first outlet are integrally formed on the water-cooled condenser liquid distribution section.

[0010] In some embodiments, the heat exchanger body further includes a drying liquid storage tank unit, and a water-cooled condenser liquid return section is provided at the second end of the water-cooled condenser body. The water-cooled condenser liquid return section is integrally formed with the drying liquid storage tank unit and communicates with the drying liquid storage tank unit; or, the drying liquid storage tank unit is integrally formed and embedded in the water-cooled condenser unit.

[0011] In some embodiments, the heat exchanger body further includes a gas-injecting enthalpy enhancer unit integrally formed between the water-cooled condenser unit and the cooler unit. The gas-injecting enthalpy enhancer unit includes a gas-injecting enthalpy enhancer body and a gas-injecting enthalpy enhancer liquid reflux section disposed at a first end of the gas-injecting enthalpy enhancer body. The first end of the gas-injecting enthalpy enhancer unit is connected to the drying storage tank unit through the gas-injecting enthalpy enhancer liquid reflux section, and the second end of the gas-injecting enthalpy enhancer unit is connected to the valve island liquid distribution unit.

[0012] In some embodiments, the integrated thermal management device based on 3D printing technology further includes a desiccant module, a filter screen, a sealing component, and an elastic limiting component. A liquid storage cylinder is integrally formed on the desiccant storage tank unit. The desiccant module and the filter screen are both located inside the liquid storage cylinder. The sealing component is fixed to the liquid storage cylinder by the elastic limiting component and is located outside the desiccant module and the filter screen.

[0013] In some embodiments, the water-cooled condenser body has a bidirectional multi-channel structure, and the multi-channel structure includes heat exchange units with 3D-printed flow channel fins or porous media.

[0014] In some embodiments, the gas replenishment enthalpy enhancer body is a bidirectional multi-channel structure, and the multi-channel structure includes 3D-printed flow channel fins or a heat exchange unit with porous media.

[0015] In some embodiments, the integrated thermal management device based on 3D printing technology further includes a distributor unit, the cooler unit includes a cooler body, a first end of the cooler body is connected to the distributor unit, the distributor unit has a liquid distribution component, the liquid distribution component is connected to the valve island distributor unit, and the distributor unit has an integrally formed second inlet and second outlet.

[0016] The second end of the cooler body is provided with a cooler exhaust section, which has an exhaust port configured to connect to the intake port of the compressor.

[0017] In some embodiments, the integrated thermal management device based on 3D printing technology further includes a gas-liquid two-phase separator unit integrally formed in the cooler unit, and the cooler unit is connected to the air intake of the compressor through the gas-liquid two-phase separator unit.

[0018] In some embodiments, the heat exchanger body is configured as at least one of the following:

[0019] The heat exchanger body is integrally printed by 3D printing equipment;

[0020] Alternatively, the heat exchanger body may have a compressor contact surface recessed on the side facing the compressor, and the compressor contact surface may be configured to fit against the outer side of the compressor housing.

[0021] In some embodiments, the integrated thermal management device based on 3D printing technology further includes a first expansion valve and a second expansion valve. The valve island liquid distribution unit is integrally formed with a first mounting port and a second mounting port. The first expansion valve is installed in the first mounting port, and the second expansion valve is installed in the second mounting port.

[0022] Secondly, a vehicle thermal management system is provided, including a compressor and an integrated thermal management device based on 3D printing technology as described above, wherein the integrated thermal management device based on 3D printing technology is installed in the housing of the compressor.

[0023] Thirdly, a vehicle is provided, including the vehicle thermal management system described above. Attached Figure Description

[0024] Figure 1 is a schematic diagram of the installation of the thermal management device and compressor provided in this application;

[0025] Figure 2 is a schematic diagram of the thermal management device provided in this application;

[0026] Figure 3 is a schematic diagram of the liquid dispenser unit provided in this application;

[0027] Figure 4 is a schematic diagram of the thermal management device provided in this application;

[0028] Figure 5 is a schematic diagram of the vehicle thermal management system provided in this application;

[0029] Figure 6 is a schematic diagram of the thermal management device provided in this application;

[0030] Figure 7 is a structural schematic diagram of the heat exchanger body provided in this application;

[0031] Figure 8 is an exploded view of the thermal management device provided in this application;

[0032] Figure 9 is a structural schematic diagram of the thermal management device provided in this application;

[0033] Figure 10 is a schematic diagram of the vehicle thermal management system provided in this application;

[0034] Figure 11 is a schematic diagram of the thermal management device provided in this application;

[0035] Figure 12 is a schematic diagram of the vehicle thermal management system provided in this application.

[0036] In the diagram: 1-Heat exchanger body; 2-Desiccant module; 3-Filter screen; 4-Sealing component; 5-Elastic limiting component; 6-First expansion valve; 7-Second expansion valve; 11-Water-cooled condenser unit; 12-Cooler unit; 13-Valve island liquid distribution unit; 14-Drying liquid storage tank unit; 15-Gas replenishment enthalpy enhancer unit; 16-Compressor mating surface; 17-Liquid distributor unit; 18-Gas-liquid two-phase separator unit; 111-Water-cooled condenser body; 112-Water-cooled condenser liquid distribution section; 113-Water-cooled condenser liquid return section; 1111-First outlet; 1112-First inlet; 121-Cooler body; 123-Cooler exhaust section; 1231-Exhaust port; 131-First mounting port; 132-Second mounting port; 133-First interface; 134-Second interface; 141-Liquid storage tank; 171-Liquid distribution component; 172-Second inlet; 173-Second outlet; 174-Liquid distribution manifold; 151-Main body of gas replenishment enthalpy enhancer; 152-Liquid reflux section of gas replenishment enthalpy enhancer; 10-Thermal management device; 20-Compressor. Detailed Implementation

[0037] In the description of this application, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. These terms are used for ease of description and simplification, 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. Furthermore, the terms "first" and "second" are used for descriptive purposes and should not be construed as indicating or implying relative importance. Specifically, the terms "first position" and "second position" refer to two different positions.

[0038] In the description of this application, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to fixed connections or detachable connections; mechanical connections or electrical connections; direct connections or indirect connections through an intermediate medium; and internal connections between two components. Those skilled in the art can understand the specific meaning of the above terms in this application depending on the specific circumstances.

[0039] As shown in Figures 1 to 10, this embodiment provides an integrated thermal management device 10 based on 3D printing technology, which can reduce the volume of the thermal management device 10 and the vehicle thermal management system, reduce the required installation space, and reduce assembly difficulty. This thermal management device 10, also referred to as a thermal management module, includes a heat exchanger body 1, which is an integrally molded component.

[0040] The heat exchanger body 1 includes an integrally formed water-cooled condenser unit 11, a cooler unit 12, and a valve island liquid distribution unit 13. The valve island liquid distribution unit 13 is located between the water-cooled condenser unit 11 and the cooler unit 12. The water-cooled condenser unit 11 can be connected to the exhaust port of the compressor 20 or to the cooler unit 12 through the valve island liquid distribution unit 13. The cooler unit 12 is configured to be connected to the suction port of the compressor 20.

[0041] The thermal management device 10 provided in this embodiment features a heat exchanger body 1 that is integrally molded. Specifically, the water-cooled condenser unit 11, cooler unit 12, and valve island distribution unit 13 of the heat exchanger body 1 are integrally molded. This allows the heat exchanger body 1 to be machined as a single unit and assembled with the compressor 20. The integration of multiple modules reduces the number of parts and eliminates the need for brazing and fastening between components, thus solving the problem of accumulated assembly tolerances, reducing assembly difficulty, and ensuring the assembly accuracy of the thermal management device 10 and the compressor 20. Furthermore, the integral molding process integrates modules such as the water-cooled condenser unit 11, cooler unit 12, and valve island distribution unit 13, resulting in high integration. This reduces the volume of the heat exchanger body 1, decreases the installation space required for the thermal management device 10, and makes better use of the vehicle's interior space. Moreover, the integral molding method minimizes the connecting channels between multiple modules, reducing heat exchange losses, improving heat exchange efficiency, and ultimately enhancing the working efficiency and reliability of the vehicle's thermal management system.

[0042] In some embodiments, the heat exchanger body 1 is integrally printed using a three-dimensional (3D) printing device. 3D printing enables the manufacture of components with complex geometries, thus allowing for the integral printing of the heat exchanger body 1 to meet the required specifications and shape. The process is simple, requires no assembly, and offers high precision. For example, a three-dimensional model of the heat exchanger body 1 to meet the required specifications and shape can be pre-built using a computer and converted into data readable by the 3D printing device. The 3D printing device then guides the layer-by-layer addition of material based on the model data, ultimately forming a three-dimensional solid.

[0043] For example, 3D printing equipment can be a fused deposition modeling (FDM) printer, a stereolithography apparatus (SLA) printer, a selective laser sintering (SLS) printer, etc.

[0044] The following describes different types of thermal management devices 10 in conjunction with Examples 1 to 5.

[0045] Example 1

[0046] As shown in Figure 2, this embodiment provides an integrated thermal management device 10 based on 3D printing technology. The heat exchanger body 1 includes an integrally formed water-cooled condenser unit 11, a cooler unit 12, and a valve island liquid distribution unit 13. Multiple modules are integrated together, reducing the number of parts and minimizing the volume of the thermal management device 10, thus reducing the space occupied by the vehicle's thermal management system. Furthermore, it eliminates the need for assembly processes between multiple parts, solving the problem of accumulated assembly tolerances, reducing assembly difficulty, ensuring the assembly accuracy of the thermal management device 10 and the compressor 20, and reducing manufacturing costs.

[0047] Referring to Figures 1 and 2, the water-cooled condenser unit 11 includes an integrally formed water-cooled condenser body 111 and a water-cooled condenser liquid distribution section 112 disposed at the first end of the water-cooled condenser body 111. The water-cooled condenser liquid distribution section 112 is connected to the valve island liquid distribution unit 13. The water-cooled condenser liquid distribution section 112 has an integrally formed first inlet 1112 and a first outlet 1111. That is, the water-cooled condenser body 111, the water-cooled condenser liquid distribution section 112, the first inlet 1112, and the first outlet 1111 of the water-cooled condenser unit 11 are integrally formed, with high integration, which is beneficial to the miniaturization design of the heat exchanger body 1. The high-temperature and high-pressure refrigerant gas discharged from the compressor 20 enters the water-cooled condenser liquid distribution section 112 through the first inlet 1112. The water-cooled condenser body 111 has a heat exchange flow channel for heat exchange between the refrigerant and the cooling medium. The high-pressure liquid refrigerant after heat exchange is output from the first outlet 1111.

[0048] In some embodiments, the water-cooled condenser body 111 has a bidirectional multi-channel structure, and the multi-channel structure includes 3D-printed flow channel fins or a heat exchange unit with porous media.

[0049] In some embodiments, referring to Figures 1, 2, and 3, the integrated thermal management device 10 based on 3D printing technology further includes a distributor unit 17. The cooler unit 12 includes a cooler body 121, with a first end of the cooler body 121 connected to the distributor unit 17. The distributor unit 17 has a liquid distribution component 171, which is connected to the valve island distributor unit 13. A second inlet 172 and a second outlet 173 are integrally formed on the distributor unit 17. A cooler exhaust section 123 is provided at the second end of the cooler body 121. The cooler exhaust section 123 has an exhaust port 1231 (referring to Figure 9), which is configured to connect to the suction port of the compressor 20. Integrating the cooler body 121, the distributor unit 17, the second inlet 172 and the second outlet 173 of the distributor unit 17, the cooler exhaust section 123, and the exhaust port 1231 of the cooler exhaust section 123 into a single unit results in high integration, which is beneficial for the miniaturization design of the heat exchanger body 1.

[0050] Referring to Figure 3, the cooler body 121 has multiple heat exchange channels, and the distributor unit 17 is equipped with multiple distribution manifolds 174. The first end of each distribution manifold 174 is connected to the liquid distribution component 171, and the second end of each distribution manifold 174 is connected to one of the heat exchange channels. The arrangement of the liquid distribution component 171 and the multiple distribution manifolds 174 can evenly distribute the medium into each heat exchange channel, making heat exchange more complete and thus improving heat exchange efficiency.

[0051] In some embodiments, the cooler body 121 has a bidirectional multi-channel structure, and the multi-channel structure includes heat exchange units with 3D-printed flow channel fins or porous media.

[0052] Example 2

[0053] This embodiment provides an integrated thermal management device 10 based on 3D printing technology, which differs from Embodiment 1 in that:

[0054] As shown in Figures 4 and 5, the heat exchanger body 1 includes an integrally formed water-cooled condenser unit 11, a cooler unit 12, a valve island liquid distribution unit 13, and a dry liquid storage tank unit 14. For vehicles with lower thermal management requirements, this thermal management device 10 has fewer parts, which can reduce the overall volume of the thermal management device 10, save installation space, and reduce production costs, making the overall vehicle thermal management system lighter.

[0055] Referring to Figure 4, the water-cooled condenser unit 11 and the refrigerant dryer tank unit 14 are integrally formed and connected to each other. The refrigerant dryer tank unit 14 is used to filter and dry the refrigerant, ensuring its heat exchange performance and improving the heat exchange efficiency of the vehicle's thermal management system. Simultaneously, the refrigerant dryer tank unit 14 can store a certain amount of refrigerant to adapt to different operating conditions of the vehicle's thermal management system.

[0056] Referring to Figures 4 and 5, a second expansion valve 7 is installed on the valve island liquid distribution unit 13. Refrigerant flows out from the discharge port of the compressor 20 and enters the water-cooled condenser unit 11. The refrigerant in the water-cooled condenser unit 11 enters the dry liquid receiver unit 14, and then, after being throttled by the second expansion valve 7, enters the cooler unit 12, finally entering the suction port of the compressor 20. The arrows in Figure 5 indicate the direction of refrigerant flow.

[0057] Example 3

[0058] This embodiment provides an integrated thermal management device 10 based on 3D printing technology, which differs from Embodiment 2 in that:

[0059] As shown in Figure 6, the heat exchanger body 1 includes an integrally formed water-cooled condenser unit 11, a cooler unit 12, a valve island liquid distribution unit 13, and a dry liquid storage tank unit 14. The dry liquid storage tank unit 14 is integrally formed and embedded within the water-cooled condenser unit 11. Embedding the dry liquid storage tank unit 14 within the water-cooled condenser unit 11 can reduce the number of components and shrink the volume of the heat exchanger body 1 while meeting the vehicle's thermal management requirements.

[0060] Example 4

[0061] This embodiment provides an integrated thermal management device 10 based on 3D printing technology, which differs from Embodiments 1, 2, and 3 in that:

[0062] As shown in Figures 1, 7, and 8, the heat exchanger body 1 includes an integrally formed water-cooled condenser unit 11, a cooler unit 12, a valve island liquid distribution unit 13, a dry liquid storage tank unit 14, and a gas injection enthalpy enhancer unit 15. The integral molding eliminates the need for assembly processes between multiple components, reducing assembly difficulty and ensuring the assembly accuracy between the thermal management device 10 and the compressor 20. Simultaneously, it reduces the volume of the heat exchanger body 1, decreases the installation space required for the thermal management device 10, makes better use of the vehicle's interior space, and improves the efficiency and reliability of the vehicle's thermal management system.

[0063] In some embodiments, the integrated thermal management device 10 based on 3D printing technology further includes a first expansion valve 6 and a second expansion valve 7. A first mounting port 131 and a second mounting port 132 are integrally formed on the valve island distribution unit 13. The first expansion valve 6 is installed in the first mounting port 131, and the second expansion valve 7 is installed in the second mounting port 132. The valve island distribution unit 13 has multiple channels configured to connect the water-cooled condenser distribution section 112, the compressor 20, and the cooler unit 12. A portion of the refrigerant from the water-cooled condenser unit 11 can enter the valve island distribution unit 13 from the water-cooled condenser distribution section 112, and then be throttled by the first expansion valve 6 and the second expansion valve 7 before flowing into the cooler unit 12 or the compressor 20. The valve island distribution unit 13, the first expansion valve 6, and the second expansion valve 7 cooperate to control the flow direction of the refrigerant, ensuring that the vehicle thermal management system can operate efficiently in different operating modes.

[0064] In some embodiments, referring to FIG9, the valve island liquid distribution unit 13 is integrally formed with a first interface 133, which is configured to connect with the exhaust port of the compressor 20 to realize the connection between the water-cooled condenser unit 11 and the compressor 20.

[0065] Referring to Figures 1, 7, and 8, a water-cooled condenser body 111 has a water-cooled condenser liquid return section 113 at its second end. The water-cooled condenser liquid return section 113 is integrally formed with and communicates with the drying liquid storage tank unit 14. The water-cooled condenser body 111, water-cooled condenser liquid distribution section 112, and water-cooled condenser liquid return section 113 of the water-cooled condenser unit 11 are integrally formed, which reduces the overall volume of the water-cooled condenser unit 11 and achieves a miniaturized design of the heat exchanger body 1. The drying liquid storage tank unit 14 is used to filter and dry the refrigerant, ensuring its heat exchange performance and improving the heat exchange efficiency of the vehicle's thermal management system. Simultaneously, the drying liquid storage tank unit 14 can store a certain amount of refrigerant to adapt to different operating conditions of the vehicle's thermal management system.

[0066] Referring to Figure 8, the integrated thermal management device 10 based on 3D printing technology also includes a desiccant module 2, a filter screen 3, a sealing element 4, and an elastic limiting element 5. A storage cylinder 141 is integrally formed on the drying storage tank unit 14. The desiccant module 2 and the filter screen 3 are both located inside the storage cylinder 141. The sealing element 4 is fixed to the storage cylinder 141 by the elastic limiting element 5 and is located outside the desiccant module 2 and the filter screen 3 to limit the desiccant module 2 and the filter screen 3 within the storage cylinder 141. The desiccant module 2 includes a drying bag and desiccant contained within the drying bag, used for drying the refrigerant. The filter screen 3 is used to filter the refrigerant, ensuring the heat exchange performance of the refrigerant. Exemplarily, the sealing element 4 is a rubber plug, and the elastic limiting element 5 is a retaining spring, ensuring that the desiccant module 2 and the filter screen 3 are securely installed within the storage cylinder 141.

[0067] Referring to Figures 1, 7, 8, and 9, the gas-injecting enthalpy enhancer unit 15 is integrally formed between the water-cooled condenser unit 11 and the cooler unit 12. The gas-injecting enthalpy enhancer unit 15 includes a gas-injecting enthalpy enhancer body 151 and a gas-injecting enthalpy enhancer liquid return section 152 disposed at the first end of the gas-injecting enthalpy enhancer body 151. The first end of the gas-injecting enthalpy enhancer unit 15 is connected to the drying liquid storage tank unit 14 through the gas-injecting enthalpy enhancer liquid return section 152, and the second end of the gas-injecting enthalpy enhancer unit 15 is connected to the valve island liquid distribution unit 13. The integrally formed design can reduce the volume of the heat exchanger body 1, making the volume of the integrated thermal management device 10 based on 3D printing technology as small as possible. In some embodiments, a second interface 134 is integrally formed on the valve island liquid distribution unit 13. The second interface 134 is configured to connect to the gas injection port of the compressor 20, realizing the connection between the gas-injecting enthalpy enhancer unit 15 and the compressor 20.

[0068] Referring to Figure 10, the refrigerant flows out of the discharge port of the compressor 20 and enters the water-cooled condenser unit 11. The refrigerant in the water-cooled condenser unit 11 then enters the dryer receiver unit 14 and the gas injection enthalpy enhancer unit 15. The refrigerant entering the gas injection enthalpy enhancer unit 15 is divided into two paths. One path of refrigerant undergoes heat exchange in the gas injection enthalpy enhancer unit 15 and is then throttled by the first expansion valve 6, entering the gas injection port of the compressor 20. The other path of refrigerant is throttled by the second expansion valve 7 and enters the cooler unit 12, finally entering the suction port of the compressor 20. The arrows in Figure 10 indicate the direction of refrigerant flow.

[0069] Optionally, referring to Figures 1, 7, 8, and 9, the cooler unit 12 includes a cooler body 121. The first end of the cooler body 121 is connected to a distributor unit 17. The distributor unit 17 has a liquid distribution component 171 (see Figure 3), which is connected to a valve island distributor unit 13. A second inlet 172 and a second outlet 173 are integrally formed on the distributor unit 17. A cooler exhaust section 123 is provided at the second end of the cooler body 121. The cooler exhaust section 123 has an exhaust port 1231, which is configured to connect to the suction port of the compressor 20. Integrating the cooler body 121, distributor unit 17, the second inlet 172 and second outlet 173 of the distributor unit 17, the cooler exhaust section 123, and the exhaust port 1231 of the cooler exhaust section 123 into a single unit results in high integration, which is beneficial for the miniaturization design of the heat exchanger body 1.

[0070] In some embodiments, the cooler body 121, the gas injection enthalpy enhancer body 151 and the cooler body 121 are bidirectional multi-channel structures, and the multi-channel structure includes heat exchange units with 3D-printed flow channel fins or porous media.

[0071] Referring to Figures 1 and 4, a compressor contact surface 16 is recessed on the side of the heat exchanger body 1 facing the compressor 20. The compressor contact surface 16 is designed to fit against the outer surface of the compressor 20 housing. The design of the compressor contact surface 16 allows the heat exchanger body 1 to fit tightly against the compressor 20, making full use of the space on both sides of the compressor 20, reducing the height of the heat exchanger body 1 and the compressor 20 after assembly (refer to the orientation in Figure 1), resulting in higher integration and reducing the space occupied by the vehicle heat exchange system.

[0072] For example, the compressor contact surface 16 is an arc-shaped surface to adapt to the shape of the outer surface of the compressor housing 20, making full use of space.

[0073] This embodiment also provides a vehicle thermal management system, including a compressor 20 and an integrated thermal management device 10 based on 3D printing technology as described above. The thermal management device 10 is installed in the housing of the compressor 20. The vehicle thermal management system using this thermal management device 10, because the heat exchanger body 1 is a one-piece molded component, integrates multiple modules, reducing the number of parts, simplifying the assembly process, avoiding the problem of accumulated assembly tolerances, reducing assembly difficulty, and ensuring the assembly accuracy of the thermal management device 10 and the compressor 20. At the same time, the one-piece molding process results in high integration, reducing the installation space required for the thermal management device 10, making reasonable use of the vehicle's internal space, and improving the working efficiency and reliability of the vehicle thermal management system.

[0074] This embodiment also provides a vehicle, including the vehicle thermal management system described above. The vehicle in this embodiment can be a gasoline-powered vehicle, a new energy vehicle, etc. Because the vehicle thermal management system has high efficiency and good reliability, it can improve the comfort and safety of the vehicle.

[0075] Example 5

[0076] This embodiment provides an integrated thermal management device 10 based on 3D printing technology, which differs from Embodiment 4 in that:

[0077] As shown in Figures 11 and 12, the heat exchanger body 1 includes an integrally formed water-cooled condenser unit 11, a cooler unit 12, a valve island liquid distribution unit 13, a gas injection enthalpy enhancer unit 15, and a gas-liquid two-phase separator unit 18. The gas-liquid two-phase separator unit 18 is integrally formed at the second end of the cooler unit 12, and the cooler unit 12 is connected to the suction port of the compressor 20 through the gas-liquid two-phase separator unit 18. This heat exchanger body 1 eliminates the need for a drying and storage tank unit 14, reducing the number of parts and allowing for a smaller size of the thermal management device 10.

[0078] In some embodiments, the first end of the gas-liquid two-phase separator unit 18 is connected to the exhaust end of the cooler unit 12, and the second end of the gas-liquid two-phase separator unit 18 is connected to the suction port of the compressor 20. Referring to Figure 12, after the refrigerant flows out of the exhaust port of the compressor 20, it enters the water-cooled condenser unit 11. The refrigerant in the water-cooled condenser unit 11 enters the gas-fuel enthalpy enhancer unit 15. The refrigerant entering the gas-fuel enthalpy enhancer unit 15 is divided into two paths. One path of refrigerant undergoes heat exchange in the gas-fuel enthalpy enhancer unit 15 and is then throttled by the first expansion valve 6. The throttled refrigerant then enters the gas-fuel port of the compressor 20. The other path of refrigerant is throttled by the second expansion valve 7 and enters the cooler unit 12. The refrigerant in the cooler unit 12 enters the gas-liquid two-phase separator unit 18. The gas separated by the gas-liquid two-phase separator unit 18 enters the suction port of the compressor 20, and the separated liquid is stored in the gas-liquid two-phase separator unit 18. This protects the compressor 20 and improves the operational reliability of the vehicle's thermal management system. The arrows in Figure 12 indicate the direction of refrigerant flow.

Claims

1. An integrated thermal management device based on 3D printing technology, comprising a heat exchanger body (1), wherein the heat exchanger body (1) is an integrally formed component; The heat exchanger body (1) includes an integrally formed water-cooled condenser unit (11), a cooler unit (12), and a valve island liquid distribution unit (13). The valve island liquid distribution unit (13) is located between the water-cooled condenser unit (11) and the cooler unit (12). The water-cooled condenser unit (11) can be connected to the exhaust port of the compressor (20) or to the cooler unit (12) through the valve island liquid distribution unit (13). The cooler unit (12) is configured to be connected to the suction port of the compressor (20).

2. The integrated thermal management device according to claim 1, wherein, The water-cooled condenser unit (11) includes an integrally formed water-cooled condenser body (111) and a water-cooled condenser liquid distribution section (112) disposed at the first end of the water-cooled condenser body (111). The water-cooled condenser liquid distribution section (112) is connected to the valve island liquid distribution unit (13). The water-cooled condenser liquid distribution section (112) has an integrally formed first inlet (1112) and a first outlet (1111).

3. The integrated thermal management device according to claim 2, wherein, The heat exchanger body (1) also includes a dry liquid storage tank unit (14). The second end of the water-cooled condenser body (111) is provided with a water-cooled condenser liquid return section (113). The water-cooled condenser liquid return section (113) is integrally formed with the dry liquid storage tank unit (14) and communicates with the dry liquid storage tank unit (14); or, the dry liquid storage tank unit (14) is integrally formed and embedded in the water-cooled condenser unit (11).

4. The integrated thermal management device according to claim 3, wherein, The heat exchanger body (1) also includes a gas-injecting enthalpy enhancer unit (15) integrally formed between the water-cooled condenser unit (11) and the cooler unit (12). The gas-injecting enthalpy enhancer unit (15) includes a gas-injecting enthalpy enhancer body (151) and a gas-injecting enthalpy enhancer liquid return section (152) disposed at the first end of the gas-injecting enthalpy enhancer body (151). The first end of the gas-injecting enthalpy enhancer unit (15) is connected to the dry liquid storage tank unit (14) through the gas-injecting enthalpy enhancer liquid return section (152). The second end of the gas-injecting enthalpy enhancer unit (15) is connected to the valve island liquid distribution unit (13).

5. The integrated thermal management device according to claim 3 or 4 further includes a desiccant module (2), a filter screen (3), a sealing member (4), and an elastic limiting member (5). The desiccant storage tank unit (14) has an integrally formed storage cylinder (141). The desiccant module (2) and the filter screen (3) are both located inside the storage cylinder (141). The sealing member (4) is fixed to the storage cylinder (141) by the elastic limiting member (5) and is located outside the desiccant module (2) and the filter screen (3).

6. The integrated thermal management device according to claim 2, wherein, The water-cooled condenser body (111) has a bidirectional multi-channel structure, which includes heat exchange units with flow channel fins or porous media formed by three-dimensional 3D printing.

7. The integrated thermal management device according to claim 4, wherein, The main body (151) of the gas replenishment enthalpy enhancer is a bidirectional multi-channel structure, which includes a heat exchange unit with 3D-printed flow channel fins or porous media.

8. The integrated thermal management device according to claim 1 further includes a distributor unit (17), wherein the cooler unit (12) includes a cooler body (121), the first end of the cooler body (121) is connected to the distributor unit (17), the distributor unit (17) has a liquid distribution component (171), the liquid distribution component (171) is connected to the valve island distributor unit (13), and the distributor unit (17) has an integrally formed second inlet (172) and a second outlet (173); The second end of the cooler body (121) is provided with a cooler exhaust section (123), the cooler exhaust section (123) has an exhaust port (1231), the exhaust port (1231) is configured to connect to the intake port of the compressor (20).

9. The integrated thermal management device according to claim 1 further includes a gas-liquid two-phase separator unit (18) integrally formed in the cooler unit (12), wherein the cooler unit (12) is connected to the suction port of the compressor (20) through the gas-liquid two-phase separator unit (18).

10. The integrated thermal management device according to any one of claims 1-9, wherein, The heat exchange body (1) is configured as at least one of the following: The heat exchanger body (1) is integrally printed by 3D printing equipment; Alternatively, the heat exchanger body (1) may have a compressor contact surface (16) recessed on the side facing the compressor (20), and the compressor contact surface (16) may be configured to contact the outer side of the casing of the compressor (20).

11. The integrated thermal management device according to any one of claims 1-10 further includes a first expansion valve (6) and a second expansion valve (7), wherein the valve island liquid distribution unit (13) is integrally formed with a first mounting port (131) and a second mounting port (132), the first expansion valve (6) is mounted in the first mounting port (131), and the second expansion valve (7) is mounted in the second mounting port (132).

12. A vehicle thermal management system, comprising a compressor (20) and an integrated thermal management device as claimed in any one of claims 1-11, the integrated thermal management device being mounted on the housing of the compressor (20).

13. A vehicle comprising the vehicle thermal management system as described in claim 12.

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