Integrated Cooling Module for Waste Heat Recovery
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Solution Overview
Problem
Conventional waste heat recovery (WHR) systems for internal combustion engines are inefficient due to their distributed nature, leading to increased complexity, space usage, and heat losses through plumbing, as well as reduced cost savings and transient capability.
Innovation Solution
An integrated cooling system for WHR that includes a frame-mounted radiator, WHR condenser, recouperator, and coolant boiler, with a compact, stacked arrangement and reduced plumbing, integrating components like a lift pump and level sensor within a single unit to enhance mass transfer efficiency and reduce leak paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If WHR heat exchangers are distributed as separate components with interconnected plumbing, then heat recovery function is achieved, but system complexity and space usage increase
Solution Approach 1:
The patent combines multiple WHR heat exchanger components into a single integrated assembly mounted on the vehicle chassis. The radiator, condenser, evaporator, and heater core are merged into one unit with common fluid pathways, eliminating the need for separate distributed components and reducing system complexity while maintaining heat recovery functionality.
Solution Approach 2:
The integrated cooling system performs multiple functions within a single assembly: it serves as a radiator for engine cooling, a condenser for refrigerant condensation, an evaporator for refrigerant evaporation, and a heater core for cabin heating. This multi-functionality reduces the number of separate components needed while achieving comprehensive thermal management.
2Reliability
If WHR heat exchangers are distributed as separate components, then heat recovery function is achieved, but on-engine space claim increases
Solution Approach 1:
The patent merges multiple heat exchanger components into a single compact integrated assembly that is mounted on the vehicle chassis in the front bumper area. This consolidation significantly reduces the total space required compared to distributing separate heat exchangers throughout the engine compartment, while maintaining all necessary heat recovery functions.
3Quantity of substance
If interconnected plumbing is used between heat exchangers, then mass transfer between components is enabled, but heat losses through plumbing increase
Solution Approach 1:
The integrated assembly incorporates internal fluid pathways that directly connect the radiator, condenser, evaporator, and heater core without requiring external plumbing. This integration eliminates long external pipes and connections, reducing heat losses through the plumbing while maintaining efficient mass transfer of coolant and refrigerant between components.
4Reliability
If conventional distributed WHR systems are used, then heat recovery is achieved, but cost savings are reduced
Solution Approach 1:
The patent integrates multiple heat exchanger components into a single manufacturable assembly, reducing the number of separate parts that need to be sourced, installed, and maintained. This consolidation lowers manufacturing costs, reduces installation complexity, and decreases maintenance requirements, thereby improving cost savings compared to conventional distributed systems.
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 system reduces on-engine space requirements, simplifies integration, and enhances cost savings and transient capability by minimizing plumbing and leak paths while maintaining efficient mass transfer and heat recovery.
Implementation Method 1
a recouperator connected to the frame above the ram air path and coupled to the WHR condenser
Implementation Method 2
a radiator connected to the frame in the path of ram air entering an engine compartment of a vehicle
Implementation Method 3
a WHR condenser connected to the frame
Implementation Method 4
a coolant boiler connected to the frame below the ram air path and coupled to the radiator and recouperator
Data Source
Figure 1
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Figure 3
AI summary
Integrated cooling systems including a frame configured for mounting to a vehicle chassis in a path of ram air entering an engine compartment of a vehicle, a radiator connected to the frame in the ram air path, a waste heat recovery (WHR) condenser, a recouperator connected to the frame above a ram air path and coupled to the WHR condenser, and a coolant boiler connected to the frame below the ram air path and coupled to the radiator and recouperator are disclosed. Cooling systems configured for use in a WHR system, including an inlet header fixedly disposed on a first end of a condenser, the inlet header fluidly coupled to a heat exchanger to receive the working fluid, and a receiver fixedly disposed on a second end of the condenser opposite the first end, the receiver configured to receive the working fluid from the condenser are also disclosed.