Dual-Loop Heat Exchanger for Electrically Isolated Vehicle Cooling
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Solution Overview
Problem
Existing vehicle heat management systems face safety risks due to the potential for electrical short circuits between cooling means and electric elements, especially in electric vehicles where excessive heat can damage components and limit current capacity, necessitating a secure and reliable heat transfer method.
Innovation Solution
A heat exchanger that thermally couples two separate cooling loops, ensuring safe heat dissipation while electrically isolating them to prevent unintended current transfer, using hollow flow plates and thermal pads for efficient heat transfer and electrical insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling means are arranged in the vicinity of electric elements to be cooled, then heat dissipation efficiency is improved, but safety risk increases due to potential electrical short circuits
Solution Approach 1:
The cooling system is divided into two separate cooling loops (first cooling loop and second cooling loop) that are electrically isolated from each other. The first cooling loop cools electric elements while the second cooling loop handles heat dissipation, preventing electrical short circuits while maintaining effective heat transfer through a heat exchanger.
Solution Approach 2:
A heat exchanger serves as an intermediary device between the first cooling loop (cooling electric elements) and the second cooling loop (heat dissipation). This intermediary enables thermal coupling while maintaining electrical isolation, allowing heat transfer without direct electrical contact between cooling components.
2Device complexity
If a single cooling loop is used for heat dissipation, then system complexity is reduced, but reliability decreases due to potential system-wide failure
Solution Approach 1:
The cooling system is segmented into two independent cooling loops with separate cooling agents and circulation paths. This segmentation ensures that a malfunction in one loop does not affect the other, improving system reliability while maintaining manageable complexity through modular design.
Solution Approach 2:
The dual-loop design provides a safety buffer by isolating potential failures to one loop at a time. The heat exchanger and electrical isolation measures prepare the system in advance to withstand malfunctions without catastrophic failure, allowing continued operation of the unaffected loop.
3Temperature
If electrically conductive cooling agents are used for efficient heat transfer, then heat exchange efficiency is improved, but electrical insulation capability deteriorates
Solution Approach 1:
The cooling system uses electrically conductive cooling agents (first cooling agent in first loop, second cooling agent in second loop) for efficient heat transfer, while the heat exchanger provides electrical isolation between the loops. This segmentation allows each loop to use optimal cooling agents without compromising overall electrical safety.
Solution Approach 2:
The heat exchanger acts as an intermediary that enables the use of electrically conductive cooling agents in both loops while preventing electrical short circuits. It transfers heat efficiently between loops while maintaining electrical isolation, allowing the system to benefit from high thermal conductivity without sacrificing electrical safety.
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 solution provides a safe and reliable heat management system that prevents electrical short circuits, ensuring only one cooling loop is affected in case of malfunction, while maintaining effective heat exchange and reducing the need for expensive dielectric cooling agents.
Implementation Method 1
heat can be dissipated from one or more vehicle elements of a vehicle to the first cooling loop and can be further dissipated from the first cooling loop to the second cooling loop via the heat exchanger
Implementation Method 2
the heat exchanger is configured to electrically isolate the first cooling loop from the second cooling loop
Data Source
Figure 1
Figure 2
Figure 3a~3d
AI summary
A heat exchanger for a vehicle heat management system comprising a first cooling loop and a second cooling loop, which is separate from the first cooling loop; wherein the heat exchanger is configured to enable a thermal coupling of the first cooling loop and the second cooling loop; wherein, in a coupled condition, the first cooling loop, the second cooling loop and the heat exchanger are configured such that heat can be dissipated from one or more vehicle elements of a vehicle to the first cooling loop and can be further dissipated from the first cooling loop to the second cooling loop via the heat exchanger, and wherein the heat exchanger is configured to electrically isolate the first cooling loop from the second cooling loop.