Gas-liquid separation device and thermal management system
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Solution Overview
Problem
Conventional gas-liquid separation devices in electric vehicle heat pump systems are heavy and costly due to metal welding processes, posing a challenge in reducing weight while maintaining functionality.
Innovation Solution
A gas-liquid separation device with a structural design featuring injection-molded components, including a first and second cylinder with a heat exchange assembly and gas-liquid separation assembly, where the second cylinder is located inside the first, and a pipe portion for liquid refrigerant return, reducing weight and enabling efficient thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal welding processes are used to manufacture gas-liquid separation devices, then the devices achieve high strength and reliability, but the weight and cost increase significantly
Solution Approach 1:
The patent changes the manufacturing method from metal welding to injection molding, fundamentally altering the production parameters and material form. This enables the creation of integrated plastic components that eliminate the need for heavy metal fasteners and welding materials while maintaining structural integrity through molded-in features
Solution Approach 2:
The patent employs composite construction by combining plastic materials for the main body with selective metal reinforcements only where absolutely necessary. The gas-liquid separation device uses a plastic shell with integrated internal structures, reducing overall weight while maintaining the strength required for refrigerant containment and separation operations
2Reliability
If metal welding processes are used to manufacture gas-liquid separation devices, then the devices achieve high reliability, but the manufacturing cost increases
Solution Approach 1:
The patent merges multiple separate metal components into a single integrated plastic housing manufactured through injection molding. The first and second housings are molded as unified structures with built-in features for mounting the gas-liquid separation assembly and heat exchange assembly, eliminating the need for separate welding operations and reducing assembly steps
Solution Approach 2:
The patent replaces the mechanical welding process with a chemical molding process. Injection molding creates permanent bonds through material fusion during the molding process itself, eliminating the need for post-manufacturing welding operations and associated costs for welding materials, equipment, and skilled labor
3Reliability
If conventional gas-liquid separation devices are used, then the basic separation function is achieved, but the liquid return function is not realized
Solution Approach 1:
The patent designs the gas-liquid separation device to perform multiple functions: gas-liquid separation, heat exchange, and liquid return. The first and second housings are configured with integrated features that enable both separation of refrigerant phases and return of liquid refrigerant to the compressor, making the device versatile for different operating conditions and system requirements
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 effectively reduces the weight of the gas-liquid separation device while maintaining its thermal management capabilities, enhancing the efficiency and longevity of electric vehicle systems by allowing for a liquid return function through the pipe portion, thus addressing the cost and weight issues of existing devices.
Implementation Method 1
A gaseous refrigerant after gas-liquid separation by the gas-liquid separation assembly enters the interlayer cavity, and then performs heat exchange with the heat exchange assembly
Implementation Method 2
the refrigerant coming out of the evaporator is generally high-temperature and low-pressure refrigerant. After the high-temperature and low-pressure refrigerant enters the gas-liquid separation device, the separated gaseous refrigerant enters the compressor
Data Source
AI summary
A gas-liquid separation device includes a first cylinder, a second cylinder, a heat exchange assembly and a gas-liquid separation assembly. The gas-liquid separation device defines a first cavity and a second cavity. The first cavity includes a space between the first cylinder and the second cylinder. The second cavity includes an inner cavity of the second cylinder. The gas-liquid separation assembly is at least partially located in the second cavity. An inner cavity of the gas-liquid separation assembly is in communication with the first cavity and the second cavity. At least part of the heat exchange assembly is located in the first cavity. The gas-liquid separation device includes a first pipe portion. A pipe cavity of the first pipe portion communicates with the second cavity and an outer space of the first cylinder. A thermal management system having the gas-liquid separation device is also disclosed.