Heat exchange device
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Solution Overview
Problem
Conventional thermal management systems for electric vehicle batteries face issues with the separation of heat exchangers and expansion valves, leading to increased weight, complex installation, poor anti-vibration performance, and high costs due to independent components and long pipelines, which affect cooling efficiency and reliability.
Innovation Solution
An integrated heat exchange device combining a heat exchanger and expansion valve with a compact, simple structure, featuring a mounting plate with specific protrusions and cavities for secure sealing and alignment, and a valve assembly with adjustable throttling orifice, eliminating the need for separate connection components and reducing vapor-liquid stratification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the heat exchanger and expansion valve are connected by pipeline and other means, then the components can be independently assembled, but the weight of the entire assembly increases and the structure becomes complicated
Solution Approach 1:
The patent combines the heat exchanger and expansion valve into a single integrated component where the expansion valve is directly mounted on the heat exchanger body. This merging eliminates the need for separate pipeline connections, reducing the overall weight and simplifying the structure while maintaining independent assembly capabilities through modular design
2Ease of manufacture
If the heat exchanger and expansion valve are connected by pipeline and other means, then the components can be independently assembled, but the installation environment becomes complicated
Solution Approach 1:
By integrating the expansion valve directly onto the heat exchanger body, the patent eliminates complex pipeline routing and connection requirements. This reduces the complexity of the installation environment and simplifies the overall installation process while preserving manufacturing independence
3Ease of manufacture
If the heat exchanger and expansion valve are connected by pipeline and other means, then the components can be independently assembled, but the anti-vibration performance becomes poor and breakage occurs
Solution Approach 1:
The integration of the expansion valve directly onto the heat exchanger body eliminates flexible pipeline connections that are susceptible to vibration-induced fatigue and breakage. The rigid integrated structure provides superior anti-vibration performance and reliability while maintaining assembly independence through standardized mounting interfaces
4Device complexity
If the vapor-liquid two-phase refrigerant passes through a long distance after the expansion valve, then the components can be separated, but vapor-liquid stratification occurs and cooling effect deteriorates
Solution Approach 1:
By positioning the expansion valve directly on the heat exchanger, the patent minimizes the distance between these components, eliminating the long pipeline that causes vapor-liquid stratification. This ensures the refrigerant maintains proper two-phase flow characteristics and achieves optimal cooling effect
5Ease of manufacture
If independent components and pipelines are used, then manufacturing flexibility is improved, but the cost increases
Solution Approach 1:
The integrated design reduces the total component count by combining the heat exchanger and expansion valve into one unit. This eliminates the need for separate pipelines, flanges, and connection hardware, thereby reducing material costs, manufacturing complexity, and overall system cost while maintaining manufacturing flexibility
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 integrated design enhances anti-vibration performance, simplifies installation, reduces costs, and improves cooling efficiency by inhibiting vapor-liquid stratification and facilitating superheat control, resulting in a more reliable and efficient thermal management system.
Implementation Method 1
the refrigerant and the coolant exchange heat in the heat exchanger
Implementation Method 2
the refrigerant and the coolant exchange heat in the heat exchanger
Implementation Method 3
the liquid refrigerant enters the heat exchanger after being throttled by the expansion valve
Data Source
AI summary
A heat exchange device includes a heat exchanger and a mounting plate for fixing the heat exchange device, and includes first and second flow passages which are not in communication with each other. The mounting plate includes a communication hole, a protruding portion and a mounting hole. The protruding portion protrudes outwards from the front side of the mounting plate. The mounting hole extends through the protruding portion and the mounting plate and includes a valve core receiving cavity. The valve core receiving cavity is in communication with the communication hole via a connection groove at a back side of the mounting plate; the mounting plate is fixed to the heat exchanger in a sealed manner, the mounting hole is in communication with the first flow passage, and the communication hole is in communication with the first flow passage via the connection groove and the mounting hole.