Composite Heat Exchange Panel With Tunable Coolant Channels
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing heat exchange systems for electronic and power equipment, particularly in vehicles, are heavy, costly, and susceptible to impact damage, lacking structural rigidity and effective coolant flow management, while requiring complex manufacturing.
Innovation Solution
A multi-layered heat exchange assembly comprising two or more panels with channels and reservoirs, a metallic or polymeric core, and adhesive material to form a customizable and tunable flow path for temperature control materials, providing structural reinforcement and impact protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If structurally rigid metal materials are used in heat exchange systems, then structural rigidity and heat exchange functionality are improved, but weight, manufacturing cost, and manufacturing time increase
Solution Approach 1:
The patent employs composite material construction by combining metal panels with polymeric or adhesive core materials. The metal panels provide necessary structural rigidity and heat conduction, while the polymeric core reduces weight and manufacturing complexity. This composite approach resolves the contradiction by achieving adequate structural strength without the full weight and cost burden of solid metal construction.
Solution Approach 2:
The heat exchange system is segmented into discrete components: metal panels, core material, and adhesive layers. This segmentation allows each component to be optimized independently - metal panels for structural rigidity and thermal conduction, polymeric core for weight reduction and channel formation, and adhesive for bonding. The segmented structure achieves the desired structural rigidity without requiring a monolithic heavy metal construction.
2Ease of operation
If complex internal cores are used to direct coolant flow, then coolant flow management is improved, but manufacturing complexity, weight, and cost increase
Solution Approach 1:
The patent merges the coolant flow direction function with the structural core material itself. Instead of using separate complex internal cores, the polymeric or adhesive core material is formulated or applied to inherently provide the desired flow channels. This merging of structural support and flow management functions into a single component dramatically reduces manufacturing complexity while maintaining effective coolant flow management.
Solution Approach 2:
The core material performs multiple functions simultaneously: it provides structural support, forms coolant flow channels, and bonds panels together. The adhesive or polymeric core material essentially serves itself by being applied in a pattern that automatically creates the flow channel network, eliminating the need for separate complex internal core components and reducing manufacturing steps.
3Reliability
If traditional heat exchange systems are used, then heat exchange functionality is provided, but impact protection and structural reinforcement are insufficient
Solution Approach 1:
The composite construction with metal panels and polymeric/adhesive core creates a structure that combines the heat exchange functionality of metal with the impact absorption characteristics of polymeric materials. The metal panels maintain thermal conduction and structural integrity, while the polymeric core provides cushioning against impact, thereby protecting the battery while maintaining heat exchange reliability.
Solution Approach 2:
The polymeric or adhesive core material acts as a pre-positioned cushioning layer between the metal panels and the battery. This cushioning is built into the structure during manufacturing, providing impact protection before any impact event occurs. The core material absorbs and distributes impact forces, protecting the battery from damage while the metal panels maintain their heat exchange function.
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 assembly achieves a lightweight, cost-effective, and impact-resistant heat exchange system with customizable coolant flow, maintaining component temperature and structural integrity.
Implementation Method 1
a coolant flows through a housing in contact with a battery to draw the excess heat from the battery. The excess heat is then transferred through the coolant
Data Source
AI summary
A heat exchange assembly comprising: (I) two or more panels; (II) a plurality of channels formed between the two or more panels; and (III) one or more reservoirs located adjacent to the plurality of channels and configured to at least temporarily store a temperature control material, wherein the plurality of channels are configured to direct a flow path of the temperature control material between the two or more panels and provide structural rigidity to the assembly.