Compact Double-Row Heat Exchanger for EV HVAC Systems
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Solution Overview
Problem
Current heat exchangers for heat pump HVAC systems in electric vehicles require significant space, limiting their compactness and efficiency.
Innovation Solution
A double-row heat exchanger design with overlapping heat exchange rows, where each row has headers enclosed between plates and tanks, with slots for tube insertion and recesses for fluid communication, allowing for a compact and efficient heat transfer configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a conventional single-row heat exchanger design is used, then the structure is simpler, but the space requirement increases
Solution Approach 1:
The patent transitions from a single-row to a double-row heat exchanger configuration, utilizing the third dimension (depth/layering) to increase heat transfer surface area within a compact footprint. The two rows are arranged in parallel with overlapping configurations, effectively doubling the heat exchange capacity without proportionally increasing the overall volume.
Solution Approach 2:
The patent employs nested integration where the second row of tubes and headers is positioned within or alongside the structural framework of the first row. The intermediate header tank and partition wall are nested between the two rows, allowing both rows to share common structural elements and fluid distribution pathways, thereby reducing total volume.
2Reliability
If headers are separately enclosed for each row, then fluid communication between rows is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the enclosure structures of both rows by introducing a common intermediate header tank that houses partition walls for both rows simultaneously. The intermediate partition wall is integrated into this shared tank, creating a unified enclosure system that provides fluid communication pathways for both rows while reducing the number of separate manufacturing operations.
Solution Approach 2:
The intermediate header tank serves multiple functions: it encloses the headers of both rows, provides the intermediate partition wall for fluid separation, creates recesses for tube insertion in both rows, and establishes fluid communication pathways. This multi-functional component simplifies the overall manufacturing process by reducing the number of separate parts that need to be produced and assembled.
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 compact design enhances space utilization while maintaining effective heat transfer efficiency, suitable for electric vehicle HVAC systems and potentially other applications requiring a compact heat exchanger structure.
Implementation Method 1
Heat exchanger, in particular inner condenser for heat pump HVAC systems
Implementation Method 2
heat exchange row comprises a first header and a second header and a plurality of parallel, coplanar tubes
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A heat exchanger comprises a first heat exchange row (10) and a second heat exchange row (20). Two header tanks (42, 52) are provided, wherein each header tank (42, 52) comprises two lateral edges (42a-42b, 52a-52b) fixedly connected to respective lateral edges of a relevant header plate (41, 51), and an intermediate edge (42c, 52c) fixedly connected to an intermediate portion (41c, 51c) of the relevant header plate (41, 51) in order to separate the respective headers of the first heat exchange row (10) and of the second heat exchange row (20) from each other. The intermediate edge (42c, 52c) of one of the header tanks has a plurality of recesses (93) which establish fluid communication between the respective headers of the first heat exchange row (10) and of the second heat exchange row (20).