Integrated Heat Exchanger Module With Shared Flow Passages
Solution Overview
Problem
Traditional thermal management systems in electric vehicles are complex and inefficient, with multiple components and lines that increase size, weight, and complexity, making them less effective in compact vehicle designs.
Innovation Solution
A compact heat exchanger module comprising a first heat exchanger configured to transfer heat between high-pressure and low-pressure fluids, a second heat exchanger in fluid communication for additional heat transfer, and a mounting plate providing fluid communication and structural integration between the heat exchangers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple heat exchangers and lines are used in traditional thermal management systems, then heat transfer functionality is achieved, but system complexity and number of components increase
Solution Approach 1:
The patent combines multiple heat exchangers (first heat exchanger for high-pressure/low-pressure fluid heat transfer and second heat exchanger for low-pressure fluid/second fluid heat transfer) into a single integrated module with shared mounting plate and fluid passages. This merging reduces the number of separate components and connections while maintaining all necessary heat transfer functions.
Solution Approach 2:
The mounting plate serves multiple functions: it provides structural support for both heat exchangers, creates fluid passages for high-pressure and low-pressure fluids, provides thermal management for multiple components simultaneously, and integrates the entire assembly into a compact unit. This multi-functionality reduces the need for separate structural and fluid distribution components.
2Ease of manufacture
If traditional thermal management components are individually placed, then each component can be optimized independently, but overall system size and weight increase
Solution Approach 1:
Multiple heat exchangers are merged into a single integrated module with common mounting plate and shared fluid distribution systems. This consolidation eliminates redundant structural components, connections, and mounting hardware that would otherwise be required for individually placed components, significantly reducing overall system weight.
Solution Approach 2:
The patent arranges the first and second heat exchangers in a nested or closely integrated configuration on the mounting plate, with fluid passages and connections optimized for compact arrangement. This nesting approach allows multiple functional components to occupy minimized space while maintaining independent optimization of each heat exchanger's internal structure.
3Reliability
If multiple lines connect individual components, then fluid flow paths are established, but the number of lines and connections increases complexity
Solution Approach 1:
The mounting plate integrates multiple fluid passages (high-pressure inlet, high-pressure outlet, low-pressure inlet, low-pressure outlet) into a single structural component. This merging of fluid distribution functions into the mounting plate eliminates the need for separate piping and connection components, reducing the number of lines while maintaining all necessary fluid flow paths.
Solution Approach 2:
The mounting plate acts as an intermediary structure that provides both mechanical support and fluid distribution functions. By incorporating internal passages and connection points directly into the mounting plate, it mediates between multiple heat exchangers and the external fluid supply/return lines, eliminating the need for numerous separate connection components.
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 compact heat exchanger module reduces the number of lines and components, enhancing efficiency and compactness, while maintaining effective heat transfer capabilities for thermal management in electric vehicles.
Implementation Method 1
The first heat exchanger is configured to transfer heat between a high-pressure fluid and a low-pressure fluid
Implementation Method 2
The second heat exchanger is in fluid communication with the first heat exchanger and is operable to transfer heat between the low-pressure fluid and a second fluid flowing through the second heat exchanger
Data Source
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AI summary
A heat exchanger module has a first heat exchanger, a second heat exchanger, and a mounting plate. The first heat exchanger has a low-pressure inlet, a low-pressure outlet, a high-pressure inlet, and a high-pressure outlet. The second heat exchanger is in fluid communication with the first heat exchanger and has a low-pressure inlet and a low-pressure outlet. The mounting plate is coupled to the first heat exchanger and the second heat exchanger. The mounting plate includes an opening which provides fluid communication between the low-pressure outlet of the second heat exchanger and the low-pressure inlet of the first heat exchanger. The mounting plate further includes a cross-over channel which connects the high-pressure outlet of the first heat exchanger to a high-pressure channel to dispense the high-pressure fluid from the first heat exchanger.