Integrated Fluid Connector Heat Exchanger for EV Battery Cooling
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Solution Overview
Problem
Existing heat exchangers for battery modules in electric vehicles are bulky due to cumbersome connections, which occupy valuable space and compromise tightness, especially during fast charging where high thermal power needs efficient dissipation.
Innovation Solution
A compact heat exchanger design featuring two plates with integrated fluid connectors, where the connector components form a fluid channel with a smooth transition from a flat to a round or elliptical cross-section, allowing for efficient heat exchange without protruding geometries, and utilizing bent teeth and wedge portions for secure connection and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional end fittings are used to connect heat exchanger panels to external fluid cooling circuits, then connection tightness is ensured, but the overall arrangement becomes bulky and occupies valuable space
Solution Approach 1:
The invention merges the connection function directly into the heat exchanger panel by integrating connection channels and connection portions into the panel structure itself. The connection channel is formed directly in the panel, and the connection portion protrudes from the panel surface, eliminating the need for separate end fittings. This integration reduces the overall volume while maintaining connection tightness through the direct structural integration.
Solution Approach 2:
The invention extracts the connection function from separate end fittings and incorporates it directly into the heat exchanger panel structure. By forming connection channels and connection portions directly in the panel, the design removes the bulky external connectors while preserving the essential connection capability, thereby reducing overall arrangement volume.
2Volume of moving object
If heat exchanger panels are made thin to reduce volume, then space efficiency is improved, but ensuring tightness of connections becomes more difficult
Solution Approach 1:
The invention combines the connection function directly into the thin panel structure by forming connection channels and connection portions within the panel itself. The connection portion protrudes from the panel surface and can be crimped or welded to connect to external fluid circuits, maintaining tightness despite the thin panel design. This integration allows thin panels to achieve both volume efficiency and connection reliability.
3Productivity
If fast charging is performed at high voltage and amperage to reduce charging time, then charging speed is improved, but thermal power increases requiring more extensive cooling surfaces
Solution Approach 1:
The invention utilizes the third dimension by forming connection channels that protrude from the panel surface and create three-dimensional fluid circulation paths. The connection portions extend outward to connect with external circuits, effectively increasing the heat exchange surface area in the vertical dimension without increasing the horizontal footprint. This allows enhanced cooling capability for fast charging applications.
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 design enhances heat transfer efficiency while minimizing bulkiness, ensuring effective cooling of battery packs during fast charging with reduced pressure drop and improved connection integrity.
Implementation Method 1
The heat exchanger comprises a first plate, a second plate attached to the first plate so that a fluid circulation space is formed between the first plate and the second plate
Implementation Method 2
a fluid circulation space is formed between the first plate and the second plate, wherein at least one fluid connector is connected fluidly with the fluid circulation space
Data Source
Figure 1~2
Figure 3~4
Figure 5a~5b
AI summary
A heat exchanger comprising a first plate (1), a second plate (2) attached to the first plate (1) so that a fluid circulation space (3) is formed between the first plate (1) and the second plate (2), at least one fluid connector (4) connected fluidly with the fluid circulation space (3), wherein the fluid connector (4) comprises a first fluid connector component (5) attached to both the first plate (1) and the second plate (2) and comprising a first shaped portion (6), wherein the second plate (2) comprises a second fluid connector component (7) comprising a second shaped portion (8) which together with the first shape portion (6) forms the fluid connector (4).