Vehicular Heat Exchanger Module Layout for Larger Modulator Capacity
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Solution Overview
Problem
Conventional heat exchanger modules face challenges in increasing the capacity of the modulator (gas-liquid separator) without enlarging the maximum outer dimension, especially when high-pressure side equipment of the vapor compression refrigerant cycle and cooling heat exchangers are combined.
Innovation Solution
The heat exchanger module arranges the condenser, sub-cooler, and heat exchanger perpendicular to the air flow direction, with the modulator extending in the same direction, allowing its dimension to be larger than the sum of the condenser and sub-cooler dimensions, and equal to or smaller than the sum of all three dimensions, thereby enhancing gas-liquid separation performance without increasing the module's outer size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the modulator capacity is increased to improve gas-liquid separation performance, then the separation performance is improved, but the maximum outer dimension of the heat exchanger module increases
Solution Approach 1:
The modulator is oriented perpendicular to the air flow direction, extending in the width direction rather than the length direction. This dimensional reorientation allows the modulator capacity to be increased without increasing the maximum outer dimension (length) of the heat exchanger module, thereby improving gas-liquid separation performance while maintaining compact overall dimensions.
Solution Approach 2:
The heat exchanger module is divided into distinct functional sections: the condenser and sub-cooler arranged in the air flow direction, and the modulator oriented perpendicular to the air flow direction. This segmentation allows each component to be optimized independently, with the modulator's capacity increased through perpendicular extension without affecting the overall module length.
2Volume of stationary object
If plural heat exchangers are arranged in the air flow direction to increase modulator capacity, then the modulator capacity increases, but the dimension of the heat exchanger module in the air flow direction becomes larger
Solution Approach 1:
Instead of extending the modulator capacity in the air flow direction (length), the modulator is oriented perpendicular to the air flow direction (width). This allows the modulator volume to be increased by utilizing the width dimension, thereby avoiding an increase in the dimension along the air flow direction while still achieving the desired modulator capacity.
3Length of stationary object
If high-pressure side equipment and cooling heat exchanger are simply combined to reduce module dimension, then the module dimension is reduced, but the function of the components cannot be sufficiently obtained
Solution Approach 1:
The module is segmented into distinct functional zones: the condenser and sub-cooler arranged in the air flow direction for thermal processing, and the modulator oriented perpendicular to the air flow direction for gas-liquid separation. This segmentation ensures that each component can perform its function effectively while the overall module dimensions are minimized through optimized spatial arrangement.
Solution Approach 2:
The modulator is positioned perpendicular to the air flow direction, creating a three-dimensional functional layout that allows sufficient gas-liquid separation capacity without increasing the module's dimension in the air flow direction. This spatial arrangement maintains component functionality while achieving compact module dimensions.
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 configuration effectively increases the modulator's capacity while preventing an increase in the heat exchanger module's maximum outer dimension, improving gas-liquid separation performance and allowing for efficient integration with other heat exchangers.
Implementation Method 1
a condenser for cooling and condensing a refrigerant
Implementation Method 2
a condenser for cooling and condensing a refrigerant
Implementation Method 3
a modulator which separates the refrigerant from the condenser into gas refrigerant and liquid refrigerant
Implementation Method 4
a sub-cooler for cooling the liquid refrigerant supplied from the modulator
Implementation Method 5
a heat exchanger for cooling a fluid different from the refrigerant
Data Source
AI summary
A heat exchanger module includes a condenser for condensing a refrigerant, a modulator, a sub-cooler for cooling liquid refrigerant supplied from the modulator, and a heat exchanger for cooling a fluid different from the refrigerant. The condenser, the sub-cooler and the heat exchanger are arranged in an arrangement direction substantially perpendicular to an air flow direction. Further, the modulator is disposed to extend in the arrangement direction. In the heat exchanger module, the modulator has a dimension that is larger than the sum of a dimension of the condenser and a dimension of the sub-cooler, and is not larger than the sum of the dimension of the condenser, the dimension of the sub-cooler and a dimension of the heat exchanger, in the arrangement direction. Accordingly, a capacity of the modulator can be effectively increased without increasing a largest outer side of the heat exchanger module.