Integrated Heat Exchanger Assembly Without Valve Connection Pipes
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Solution Overview
Problem
Conventional battery cooling systems for electric automobiles have a complex connection structure between the plate heat exchanger and thermal expansion valve, leading to a large volume, high cost, poor vibration-proof performance, heavy weight, and reduced refrigeration efficiency due to the use of connection pipes.
Innovation Solution
A heat exchanger integrated assembly is developed with a direct connection to the expansion valve through a mating portion and an adaptor, eliminating the need for pipes, featuring a simple structure, improved vibration-proof performance, and reduced weight and cost, while maintaining effective refrigeration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If connection pipes are used to connect the plate heat exchanger and thermal expansion valve, then the connection structure is flexible, but the assembly volume increases and installation becomes inconvenient
Solution Approach 1:
The patent integrates the thermal expansion valve directly onto the plate heat exchanger by forming a valve body that combines both components. The connection pipes are eliminated and the valve is mounted directly on the heat exchanger plates, merging two separate components into one integrated assembly, thereby reducing overall volume while maintaining connection functionality
Solution Approach 2:
The integrated valve body serves multiple functions: it acts as both the thermal expansion valve and the connection structure. The valve body incorporates inlet and outlet ports that directly interface with the heat exchanger passages, eliminating the need for separate connection pipes and reducing assembly complexity
2Reliability
If connection pipes are used to connect the plate heat exchanger and thermal expansion valve, then the connection is achievable, but the number of parts increases and cost rises
Solution Approach 1:
The patent reduces the number of parts by integrating the thermal expansion valve directly onto the plate heat exchanger. The valve body is formed as a single integrated component that combines the valve mechanism with the connection structure, eliminating multiple separate parts including connection pipes, flanges, and fasteners, thereby reducing both part count and manufacturing cost
3Reliability
If connection pipes are used to connect the plate heat exchanger and thermal expansion valve, then the connection structure is complete, but the assembly has poor vibration-proof performance and pipe ruptures occur
Solution Approach 1:
The patent eliminates connection pipes by integrating the valve directly onto the heat exchanger plates. The valve body is welded or mechanically fastened directly to the plate assembly, creating a rigid, unified structure that eliminates the flexible pipe connections prone to vibration damage and rupture, thereby improving vibration resistance while maintaining connection integrity
4Reliability
If connection pipes and materials are added, then the connection is achievable, but the assembly weight increases
Solution Approach 1:
The patent reduces assembly weight by eliminating connection pipes and additional materials. The thermal expansion valve is integrated directly onto the heat exchanger plates, removing the need for separate piping materials, flanges, and fasteners, thereby reducing overall assembly weight while maintaining connection feasibility through the integrated valve body structure
5Reliability
If connection pipes are used, then the flow path is established, but the refrigeration effect is adversely affected
Solution Approach 1:
The patent improves refrigeration efficiency by eliminating connection pipes that cause pressure drops and thermal losses. The refrigerant flows directly from the heat exchanger plates through the integrated valve body without intermediate pipe connections, reducing energy losses and maintaining better refrigeration effect while establishing the necessary flow path
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 results in a compact, easy-to-install heat exchanger assembly with enhanced vibration-proof performance and improved refrigeration efficiency, reducing the risk of pipe ruptures and lowering overall weight and cost.
Implementation Method 1
the heat exchanger includes a first flow passage and a second flow passage, and the first flow passage includes a first inlet and a first outlet
Implementation Method 2
the refrigerant cools the cooling liquid via the plate heat exchanger
Implementation Method 3
the mating portion includes a first side facing the heat exchanger, a second side facing the adaptor, and a first hole and a second hole both running through the first side and the second side
Data Source
AI summary
A heat exchanger integrated assembly and a manufacturing method thereof are provided. The heat exchanger integrated assembly includes a heat exchanger, a mating portion and an adaptor, wherein the heat exchanger includes a first inlet and a first outlet; the mating portion includes a first side, a second side and a first hole and a second hole passing through the first side and the second side, and the mating portion further includes a first recessed portion formed on the first side and in communication with the first hole; and the adaptor includes a first passage in communication with the first hole and in communication with the first inlet via the first recessed portion, and a second passage in communication with the first outlet via the second hole. The heat exchanger is integrated with other parts and is connected to an expansion valve directly.