Dual Expansion Valve for Independent Vehicle Heat Exchanger Control

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Solution Overview

Problem

Refrigerant cycles in cooling/heating systems for vehicles face high complexity and cost, with inefficient cooling performance and limited flexibility in controlling heat exchanger performance due to mutual dependency between heat exchangers and the use of complex electrical expansion devices.

Innovation Solution

A dual expansion valve system with a movable rod controlling two flow restriction mechanisms, allowing independent control of refrigerant streams and thermal management, reducing complexity and cost by eliminating the need for electrical actuators.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If electrical expansion devices are used to control refrigerant flow, then the precision of refrigerant flow control is improved, but the device complexity and cost increase

Engineering Contradiction:

Improverefrigerant flow control precisionVSAvoidsystem complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces electrical expansion devices with a purely mechanical dual expansion valve system. The valve uses a shared movable rod connected to two separate valve elements through mechanical linkages, eliminating the need for electrical actuators while maintaining precise control over refrigerant flow to multiple heat exchangers.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The dual expansion valve performs multiple functions simultaneously: it controls refrigerant flow to two different heat exchangers, enables independent thermal management of each heat exchanger, and provides precise flow regulation without requiring separate electrical control systems for each channel.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If multiple heat exchangers are used for thermal management, then the adaptability of the system is improved, but the mutual dependency between heat exchangers limits flexibility

Engineering Contradiction:

Improvethermal management flexibilityVSAvoidheat exchanger interdependence

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent segments the refrigerant flow control into two independent channels, each with its own expansion valve element. This segmentation allows each heat exchanger to be controlled independently through its dedicated valve element, eliminating mutual dependency while maintaining system integration through the shared valve body and movable rod mechanism.

Inventive Principle:

Principle #1Segmentation

3Manufacturing precision

If complex electrical expansion devices are used, then the control precision is improved, but the manufacturing cost increases

Engineering Contradiction:

Improveflow control precisionVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent employs a cost-effective mechanical design using simple, durable components such as a shared movable rod, spring elements, and mechanical linkages instead of expensive electrical actuators. These mechanical components are easier to manufacture, require less maintenance, and reduce overall system cost while delivering precise flow control.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 dual expansion valve enhances cooling efficiency by allowing independent operation of heat exchangers and reduces costs by simplifying the system, enabling optimal performance and heat transfer control.

Implementation Method 1

a first heat exchanger arranged to provide heat exchange between a refrigerant circuit and a coolant circuit

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Implementation Method 2

a first flow restriction mechanism including a movable first valve element, by which a first refrigerant stream flowing through a first passage from the first inlet to the first outlet can be controlled

Methodology Applied

Scientific EffectFlow restriction: Valve

Data Source

PatentUS11221164B2Heat exchange system and refrigerant cycle including heat exchange system

Publication Date: 2022.01.11 DENSO AUTOMOTIVE DEUT GMBH

AI summary

A heat exchange system includes a dual expansion valve for a refrigerant cycle of a vehicle that includes a first inlet and a first outlet, a first flow restriction mechanism including a movable first valve element, by which a first refrigerant stream flowing through a first passage from the first inlet to the first out let can be controlled, a second inlet and a second outlet, a second flow restriction mechanism including a movable second valve element, by which a second refrigerant stream flowing through a second passage from the second inlet to the second outlet can be controlled, a control member for jointly moving the first valve member and the second valve member, a sensing element for sensing a temperature, and a valve driving member that is configured to drive the control member according to the sensed temperature.