Injection-type heat exchange module and vehicle thermal management system using same
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Solution Overview
Problem
Electric vehicles require separate heating, decreasing fuel efficiency and increasing the need for frequent battery charging, as they lack an engine-based heat source, and existing gas injection-type heat pumps require separate mounting of heat exchangers and accumulators with complex control systems.
Innovation Solution
An integrated injection-type heat exchange module that combines a heat exchanger and flash tank, featuring an outer tank with separated chambers, an inner tank for heat exchange, and valves operated by a single actuator to control refrigerant flow and expansion, simplifying the system configuration and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If separate heat exchanger and accumulator are mounted individually, then system functionality is maintained, but device complexity and mounting complexity increase
Solution Approach 1:
The patent combines the heat exchanger and accumulator into a single integrated module, eliminating the need for separate mounting of these components. The merged structure reduces system complexity and number of parts while maintaining the distinct functional zones for heat exchange and refrigerant accumulation.
Solution Approach 2:
The integrated module serves multiple functions simultaneously: the outer tank acts as both heat exchanger and accumulator, the inner tank provides secondary heat exchange and refrigerant storage, and the shared refrigerant channels enable both heating and cooling operations through a single unified structure.
2Device complexity
If multiple expansion valves are used for precise refrigerant control, then refrigerant flow control precision is improved, but device complexity and control system complexity increase
Solution Approach 1:
The patent replaces multiple expansion valves with a single expansion valve that controls refrigerant flow to both the inner and outer tanks. This unified control mechanism simplifies the control system while maintaining precise refrigerant distribution through the integrated thermal coupling between tanks.
Solution Approach 2:
The system utilizes the natural thermal interaction between the inner and outer tanks to automatically distribute refrigerant. The thermal coupling allows heat and refrigerant to flow between tanks based on temperature differences, reducing the need for complex active control mechanisms.
3Productivity
If gas injection is performed to increase circulating refrigerant amount, then heating efficiency is improved, but energy consumption in compressor increases
Solution Approach 1:
The patent utilizes phase change of refrigerant between liquid and gas states during the injection cycle. Refrigerant is expanded to low-pressure gas phase, injected into the compressor to increase mass flow, then condensed back to liquid phase, leveraging natural phase transitions to enhance heating efficiency.
Solution Approach 2:
The system dynamically changes refrigerant parameters (pressure, temperature, phase) through controlled expansion and injection cycles. By adjusting expansion ratios and injection timing, the system optimizes the balance between increased refrigerant circulation for heating and compressor energy consumption.
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 module enhances heating efficiency by increasing the amount of circulating refrigerant during heating, reducing the need for separate heaters and improving overall thermal management in electric vehicles.
Implementation Method 1
an inner tank arranged inside the outer tank in such a manner that heat exchange with the refrigerant inside the outer tank possibly takes place
Data Source
AI summary
An injection-type heat exchange module includes an outer tank configured with upper and lower chambers, the upper chamber being connected in such a manner that refrigerant is introduced thereinto from an outer condenser or an inner condenser, and the lower chamber being connected in such a manner that the refrigerant is introduced thereinto from an evaporator and that the refrigerant is discharged therefrom to a compressor, an inner tank arranged inside the outer tank and connected in such a manner that the refrigerant is discharged therefrom to the compressor or the evaporator; a first valve arranged in an upper end portion of the inner tank, a second valve arranged in a lower end portion thereof, and an actuator connected to both the first valve and the second valve and operating in such a manner that the first and second valves are rotated at the same time.