Ceramic-Insulated Heat Exchanger Terminal Block for Radiant Heat Shielding
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Solution Overview
Problem
Heat transfer, particularly by radiation, between heat exchangers in close proximity can lead to thermal deterioration and physical damage, especially to plastic components, due to the limited available volume in motor vehicle heat exchanger assemblies.
Innovation Solution
A connection block for heat exchangers featuring an outer layer made of alumina or ceramic materials, which insulates the body to limit heat transfer, especially by radiation, between the connection block and its environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If heat exchangers are assembled close together to minimize volume, then the volume of the heat exchanger assembly is reduced, but heat transfer by radiation between heat exchangers causes thermal deterioration and physical damage to components
Solution Approach 1:
The patent introduces a reflective barrier (aluminum foil or radiant barrier material) positioned between the connection block and adjacent heat exchanger components. This intermediary layer reflects thermal radiation back toward the connection block, preventing heat transfer to plastic portions and other sensitive components, thereby resolving the harmful thermal radiation effect while maintaining compact assembly volume.
Solution Approach 2:
The connection block employs a composite structure combining metal (aluminum or stainless steel) for structural integrity and thermal management with a reflective barrier layer (aluminum foil or radiant barrier material) for thermal radiation control. This composite approach allows the connection block to withstand high temperatures while protecting adjacent components from radiant heat, enabling compact assembly without thermal damage.
2Volume of moving object
If the connection block is positioned near additional heat exchangers to reduce assembly volume, then the overall assembly volume is minimized, but the connection block causes heat damage to nearby plastic components through radiation
Solution Approach 1:
The reflective barrier (aluminum foil or radiant barrier material) serves as a protective intermediary between the high-temperature connection block and adjacent plastic components. This barrier reflects thermal radiation away from plastic portions, preventing thermal degradation and maintaining component integrity while allowing the connection block to be positioned in close proximity for compact assembly.
Solution Approach 2:
The reflective barrier is pre-installed on or around the connection block before final assembly, creating a protective shield that prevents thermal radiation damage to plastic components before they are exposed to harmful heat levels. This proactive protection ensures component integrity is maintained throughout operation.
3Use of energy by moving object
If high temperature fluid circulates through the heat exchanger to improve thermal performance, then heat exchange efficiency is enhanced, but heat transfer by radiation damages components near the connection block
Solution Approach 1:
The reflective barrier (aluminum foil or radiant barrier material) intercepts thermal radiation generated by high-temperature fluid circulation in the heat exchanger, reflecting it back toward the connection block and preventing damage to adjacent components. This allows high-temperature operation for improved heat exchange efficiency without compromising component safety.
Solution Approach 2:
The reflective barrier changes the thermal radiation parameters by reflecting rather than absorbing radiant heat, effectively redirecting thermal energy that would otherwise damage plastic components. This parameter change enables the system to operate at higher temperatures for improved efficiency while protecting sensitive components from thermal damage.
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 outer layer effectively reduces heat exchange between the connection block and adjacent components, preventing damage and improving thermal performance while maintaining assembly compactness.
Implementation Method 1
the outer layer is configured to thermally insulate said body
Implementation Method 2
heat transfer, particularly by radiation, between heat exchangers within the same assembly
Data Source
Figure 1
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AI summary
The invention relates to a connection block (1) of a heat exchanger (100), in particular a gas cooler, for a vehicle, in particular an electric vehicle, comprising: - a body (10), - at least one passage (11) configured to fluidly connect the heat exchanger (100) to a fluid circuit, - an outer layer (20) covering at least partially said body (10), said connection block (1) being characterized in that the outer layer (20) is configured to thermally insulate said body (1), said outer layer (20) comprising in particular alumina or ceramic, in particular a plurality of ceramic spheres.