Dual Plate Heat Exchanger Flow Distribution for Stable Medium Loads
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Solution Overview
Problem
Existing plate heat exchangers in electric and hybrid vehicles face challenges in maintaining optimal thermal power across varying usage loads, particularly experiencing a drop in thermal power during medium loads due to poor fluid distribution and flow rates.
Innovation Solution
A heat energy exchange device comprising two plate heat exchangers with a distribution member that includes channels connecting inlet and outlet ports, featuring a fluid expansion device and pressure/temperature sensors, allowing for efficient heat transfer fluid management and distribution between the exchangers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a large plate heat exchanger is used to meet high cooling power requirements, then thermal power exchange capability is improved, but thermal power collapses at medium load due to poor fluid distribution
Solution Approach 1:
The system divides the heat exchange function into two separate plate heat exchangers (first and second exchangers) with different sizes, each optimized for specific load ranges. The distribution member segments the fluid flow to direct appropriate flow rates to each exchanger based on operating conditions, preventing thermal power collapse at medium loads while maintaining high capability at peak loads.
2Productivity
If fast battery charging is implemented to improve electric mobility acceptance, then charging speed is improved, but heat dissipation requirements increase significantly
Solution Approach 1:
The distribution member dynamically adjusts fluid flow distribution between the two plate heat exchangers based on real-time operating conditions. During fast charging with high heat dissipation requirements, the system activates both exchangers with optimized flow rates to provide maximum cooling capacity, then transitions to single exchanger operation during normal charging to maintain efficiency.
3Power
If a single large plate heat exchanger is used, then high load cooling capability is improved, but device complexity is reduced
Solution Approach 1:
The distribution member merges the functions of flow distribution, flow rate control, and thermal power optimization into a single integrated component. This consolidates multiple potential components (separate flow meters, valves, and control systems) into one unit, managing the complexity of operating two heat exchangers while maintaining high load cooling capability.
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 ensures optimal thermal power performance across different usage loads by enhancing heat transfer efficiency and fluid distribution, addressing the limitations of oversized heat exchangers during medium load conditions.
Implementation Method 1
each plate heat exchanger being configured to allow heat energy exchanges between at least two heat transfer fluids at different temperatures
Implementation Method 2
heat energy exchanges between a heat transfer fluid circulating in a battery thermal management loop and a low-pressure refrigerant circulating in the air conditioning circuit
Implementation Method 3
the distribution member comprising a heat transfer fluid expansion device fixed to said heat transfer fluid inlet connection orifice
Implementation Method 4
a heat transfer fluid pressure and/or temperature sensor being inserted into said opening
Implementation Method 5
a heat transfer fluid pressure and/or temperature sensor being inserted into said opening
Data Source
Figure 1
Figure 2
Figure 3a
AI summary
Heat-energy exchange device (1) comprising a first (100) and a second (200) plate heat exchanger, each plate heat exchanger (100, 200) being configured to allow exchanges of heat energy between at least two heat-transfer fluids at different temperatures, said exchange device (1) further comprising a distribution member (3) sandwiched between the first (100) and second (200) plate heat exchangers, said distribution member (3) comprising a series of channels (31, 32, 33, 34, 35, 36, 37, 38) made within it, said channels (31, 32, 33, 34, 35, 36, 37, 38) connecting inlets and outlets of heat-transfer fluid of the first (100) and second (200) plate heat exchangers to connection orifices (31a, 32a, 33a, 34a, 35a, 36a, 37a, 38a) positioned on said distribution member (3).