Integrated Vehicle Heat-Treatment Module for Fewer Pipe Leaks
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Solution Overview
Problem
Existing heat treatment systems in electric and hybrid vehicles are bulky, require numerous pipes that are prone to leaks and heat dissipation, and have long assembly times.
Innovation Solution
A unitary heat treatment module integrating an internal heat exchanger, a heat exchanger, and a mounting block, minimizing pipe connections and optimizing heat exchange through U- or X-shaped circulation paths and brazed connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a heat treatment system uses numerous pipes to connect components of refrigerant circuit and heat transfer fluid circuit, then the system can perform heat exchange functions, but the system becomes bulky and assembly time increases excessively
Solution Approach 1:
The patent combines the heat exchanger, internal heat exchanger, and expansion member into a single integrated heat treatment module. This merging eliminates the need for numerous separate pipes and connections between these components, directly reducing assembly time and system complexity while maintaining all necessary heat exchange functions.
Solution Approach 2:
The integrated module serves multiple functions simultaneously: the heat exchanger performs heat exchange between refrigerant and heat transfer fluid, the internal heat exchanger performs heat exchange at two different temperature levels, and the expansion member provides refrigerant expansion. This multi-functionality within a single module reduces the number of separate components and connections required.
2Reliability
If numerous pipes are used to connect heat treatment system components, then heat exchange functions are enabled, but the system becomes prone to leaks of heat transfer fluid and refrigerant
Solution Approach 1:
By integrating the heat exchanger, internal heat exchanger, and expansion member into a single module with internal connections, the patent eliminates multiple external pipe connections that are susceptible to leaks. The refrigerant and heat transfer fluid pathways are contained within the integrated structure, significantly improving reliability.
3Loss of energy
If numerous pipes are used in the heat treatment system, then component connections are achieved, but heat dissipation affects the overall efficiency of the heat treatment system
Solution Approach 1:
The integrated module design minimizes the length and surface area of external pipes and connections. By containing the refrigerant and heat transfer fluid pathways within the compact module structure, the patent reduces unwanted heat dissipation to the surrounding environment, thereby improving overall system efficiency.
4Productivity
If a heat treatment system uses separate components connected by pipes, then the system can be assembled with standard components, but assembly times become excessively long
Solution Approach 1:
The patent integrates multiple components into a single heat treatment module that can be manufactured as one unit or pre-assembled. This integration dramatically reduces assembly time during vehicle installation, as the entire module can be installed as a single unit rather than connecting multiple separate components with numerous pipes.
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 reduces system complexity, minimizes leaks and heat dissipation, and shortens assembly time while maintaining efficient heat exchange.
Implementation Method 1
The heat exchanger is configured to perform heat exchange between the heat transfer fluid and the refrigerant
Implementation Method 2
heat exchange between the refrigerant and the heat transfer fluid inside the heat exchanger
Implementation Method 3
heat exchange between the refrigerant and the heat transfer fluid inside the heat exchanger
Implementation Method 4
The internal heat exchanger is configured to perform heat exchange between the refrigerant, which is subjected to two different temperature levels within the thermal treatment system
Implementation Method 5
heat exchange between the refrigerant at two different temperature levels
Implementation Method 6
heat exchange between the refrigerant at two different temperature levels
Implementation Method 7
The first face is brazed onto the end plate of the heat exchanger
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention relates to a heat-treatment unit module (1) for a heat-treatment system for a vehicle. The heat-treatment unit module (1) comprises a heat exchanger (3) and an internal heat exchanger (4). The heat exchanger (3) is configured to perform a heat exchange between a heat-transfer liquid (5) and a refrigerant (6). The internal heat exchanger (4) is configured to perform a heat exchange between the refrigerant (6) which has been subjected in the heat-treatment system to two different temperature levels (T1, T2). The heat-treatment module (1) comprises an attachment block (7) at least rigidly connected to the heat exchanger (3) and arranged to support an expansion member (8), the heat exchanger (3) being inserted between the internal heat exchanger (4) and the attachment block (7).