Multi-Mode Heat Exchanger With Adjustable Refrigerant Passes
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Solution Overview
Problem
Conventional chillers for electric vehicle battery packs face challenges in efficiently managing heat dissipation and heating requirements due to significant pressure drops when operating in heating mode, necessitating a flexible configuration of refrigerant passes through heat exchange tubes without movable parts.
Innovation Solution
A heat exchanger system with adjustable manifold configurations allows selective control of refrigerant passes through heat exchange tubes, enabling four-pass or two-pass configurations based on cooling or heating needs, using a controller to switch between modes without movable parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the refrigerant is made to traverse a higher number of passes through the heat exchanging tubes in heating mode, then the heat exchange effectiveness is improved, but the pressure drop of the gaseous refrigerant increases significantly
Solution Approach 1:
The patent implements a dynamic configuration system where the number of refrigerant passes through heat exchange tubes can be changed based on operating mode. The manifold assembly includes configurable flow paths that allow switching between multiple-pass configuration for cooling mode and fewer-pass configuration for heating mode, adapting the system dynamics to match operational requirements and minimize pressure drop while maintaining heat exchange effectiveness.
Solution Approach 2:
The system changes the operational parameter of refrigerant passes by reconfiguring the manifold connections. In cooling mode, the refrigerant is directed through multiple passes (e.g., 4-pass or 6-pass) to maximize heat exchange. In heating mode, the manifold is reconfigured to allow fewer passes (e.g., 2-pass) for gaseous refrigerant, thereby reducing pressure drop while still achieving effective heat transfer.
2Reliability
If a separate heat exchanger is commissioned for heating the battery, then the heating function is achieved, but the space requirement and device complexity increase
Solution Approach 1:
The patent designs the chiller assembly with a universal manifold system that can serve dual functions: cooling mode with multiple refrigerant passes and heating mode with fewer refrigerant passes. The same heat exchange tubes and core structure are utilized in both modes by reconfiguring the manifold connections, eliminating the need for a separate heat exchanger and reducing overall device complexity while maintaining both cooling and heating capabilities.
Solution Approach 2:
The invention merges the cooling and heating functions into a single integrated chiller assembly. The manifold assembly combines multiple flow path configurations within one structure, allowing the system to switch between cooling (multiple passes) and heating (fewer passes) operations using the same physical components, thereby consolidating what would traditionally require separate devices.
3Reliability
If the refrigerant passes through multiple heat exchange tubes in liquid state, then the pressure drop is low and heat exchange is effective, but this configuration is not suitable for gaseous refrigerant in heating mode
Solution Approach 1:
The manifold assembly is designed with dynamic reconfigurability to adapt to different refrigerant states. The system can switch between a multi-pass configuration optimized for liquid refrigerant during cooling and a fewer-pass configuration optimized for gaseous refrigerant during heating, making the system adaptable to varying operational conditions without compromising performance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively manages heat exchange by minimizing pressure drops during heating while maintaining efficiency in cooling, adapting to varying thermal demands of the battery pack.
Implementation Method 1
The core of the heat exchanger includes a plurality of heat exchange tubes fluidically connecting the first manifold and the second manifold allowing refrigerant to pass therein. The heat exchange tubes are configured for heat exchange between the refrigerant flowing there through and the coolant that is in fluidic contact with the heat exchange tubes.
Implementation Method 2
The coolant received inside the housing undergoes heat exchange with the heat exchange tubes by being in contact therewith.
Data Source
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AI summary
A heat exchanger (100) includes a housing (10), a first manifold (20), a second manifold (30, 130) and a core (40). The housing (10) defines an enclosure and comprises nozzles (14, 16) for ingress and egress of coolant inside the housing (10). The first manifold (20) includes ports (222) and channels (242) in fluidic communication with the corresponding ports (222). Each channel (242) includes different sets of apertures (244). The second manifold (30, 130) is disposed substantially opposite to the first manifold (20). The core (40) includes heat exchange tubes (42) in fluid communication with the first manifold (20) and the second manifold (30, 130). The different set of apertures (244) configure fluid communication between the channels (242) and the heat exchange tubes (42) based on operative configuration of the ports (222) controlled by a controller (60) to define the number of passes through the core (40).