EV Heat Exchanger Bypassing Bottle to Reduce Pressure Loss
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Solution Overview
Problem
Existing heat exchangers for electric vehicles face inefficiencies in both heat pump and condenser modes, with refrigerant flow through a 'bottle' causing undesirable pressure losses and component deterioration, and lack a compact design integrating both modes effectively.
Innovation Solution
A heat exchanger design featuring a first and second manifold with flat tubes and a bottle, allowing fluid communication through multiple passes and blocks, enabling efficient operation in both heat pump and condenser modes by directing fluid flow to bypass the bottle in heat pump mode and utilize it in condenser mode, with insulating means between passes to enhance efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If refrigerant flows through the bottle in heat pump mode, then the heat exchanger can operate in both condenser and heat pump modes using a single component, but this causes undesirable pressure losses and component deterioration
Solution Approach 1:
The heat exchanger is divided into multiple passes (first pass, second pass, third pass) with separate block connections. The bottle is fluidly connected to the first manifold but not required for heat pump mode operation. In heat pump mode, refrigerant flows through blocks directly connected to the first manifold, bypassing the bottle. In condenser mode, the bottle becomes part of the flow path. This segmentation allows mode-specific flow paths that optimize performance for each operation mode.
Solution Approach 2:
The system dynamically switches flow paths between different operational modes. Valves or flow control mechanisms enable the refrigerant to follow different routes: in heat pump mode, flow goes through blocks connected to the first manifold without entering the bottle; in condenser mode, flow is directed through the bottle. This dynamic adaptability eliminates unnecessary pressure losses in heat pump mode while maintaining dual-mode versatility.
2Adaptability or versatility
If refrigerant flows in reversed direction between condenser and heat pump modes, then the heat exchanger can adapt to different operational requirements, but this increases the deterioration of the bottle components
Solution Approach 1:
The heat exchanger is divided into multiple passes (first pass, second pass, third pass) with separate block connections. The bottle is fluidly connected to the first manifold but not required for heat pump mode operation. In heat pump mode, refrigerant flows through blocks directly connected to the first manifold, bypassing the bottle. In condenser mode, the bottle becomes part of the flow path. This segmentation allows mode-specific flow paths that optimize performance for each operation mode.
Solution Approach 2:
The bottle is extracted from the mandatory flow path in heat pump mode. By providing alternative flow paths through blocks connected to the first manifold, the bottle is taken out of the refrigerant flow during heat pump operation. This eliminates stress and deterioration on the bottle components during frequent heat pump cycles, while the bottle remains available for use in condenser mode when needed.
3Device complexity
If a compact design integrating both operational modes is implemented, then space and component count are reduced, but the complexity of managing different flow paths increases
Solution Approach 1:
The heat exchanger merges condenser and heat pump functionalities into a single integrated component. Multiple blocks are fluidly connected to the first manifold, creating a unified structure that handles both operational modes. The bottle is integrated into the first manifold but only activates for condenser mode, while heat pump mode uses direct block connections. This merging reduces overall system complexity compared to having separate components for each mode.
Solution Approach 2:
The first manifold and connected blocks serve universal functions for both condenser and heat pump modes. The same structural components handle refrigerant flow in both operational configurations, eliminating the need for mode-specific components. The bottle and blocks are multi-functional elements that adapt their role based on operational requirements, simplifying the overall system architecture while maintaining ease of operation through consistent component interfaces.
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
This design enhances the overall efficiency of the heat exchanger, reduces component stress, and integrates both operational modes into a single compact system, improving energy efficiency and reducing energy consumption in electric vehicles.
Implementation Method 1
a heat exchanger for heat exchange between a first fluid and a second fluid
Implementation Method 2
a plurality of flat tubes stacked between the first manifold and the second manifold, the plurality of flat tubes being configured to provide the fluidal communication
Implementation Method 3
the flat tubes comprise at least one insulating means located between the first and the third pass
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The object of the invention is, among others, a heat exchanger (1) for heat exchange between a first fluid and a second fluid comprising: a first manifold (100) and a second manifold (200) spaced apart from the first manifold (100), wherein the second manifold (200) is substantially parallel with respect to the first manifold(100), a plurality of flat tubes (300) stacked between the first manifold (100) and the second manifold (200), the plurality of flat tubes (300) being configured to provide the fluidal communication between the first manifold (100) and the second manifold (200), a bottle (400) fluidly connected to the first manifold (100), the bottle (400) comprising at least one passage (401) for the fluid, wherein the heat exchanger (1) comprises a first block (10) and a second block (20), both first and second blocks (10, 20) being fluidly connected to the first manifold (100), and at least one third block (30) fluidly connected to the first manifold (100) or the second manifold (200).