Integrated Plate Heat Exchanger for Compact EV A/C Packaging
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Solution Overview
Problem
Existing air conditioning systems for vehicles face challenges with complex integration of components, increased costs due to additional coolant circulation systems, and complicated assembly processes, particularly in electric vehicles with low waste heat temperatures.
Innovation Solution
A compact heat exchanger unit integrating a condenser region, high-pressure refrigerant collector region, and excess cooling region as a single, plate-packeted component, allowing for efficient refrigerant condensation and collection, with thermally insulated regions and a simplified refrigerant circulation system, reducing the need for external connections and minimizing leakage risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a water-cooled condenser is used to improve heat exchange efficiency and reduce size, then heat exchange efficiency is improved and condenser size is reduced, but additional coolant circulation system increases device complexity and cost
Solution Approach 1:
The patent combines the engine coolant circulation system and air conditioning coolant circulation system into a single integrated system. The engine cooler and air conditioning condenser share common coolant circulation paths, eliminating the need for separate coolant pumps, reservoirs, and control systems while maintaining efficient heat exchange for both functions.
Solution Approach 2:
The coolant circulation system is designed to serve multiple functions simultaneously - cooling the engine, condensing refrigerant in the air conditioning system, and providing climate control. This multi-functional approach allows a single system to replace what would traditionally require separate dedicated systems.
2Adaptability or versatility
If components are integrated in various places inside the vehicle to meet spatial requirements, then spatial adaptability is improved, but assembly complexity increases due to complicated work sequence
Solution Approach 1:
The air conditioning system is divided into modular components including the evaporator assembly, condenser assembly, and expansion valve assembly. Each module can be independently manufactured, tested, and assembled into the vehicle, simplifying the overall assembly process while allowing flexible spatial arrangement within the vehicle interior.
Solution Approach 2:
The patent employs nested arrangements where smaller components are integrated within or alongside larger components. For example, the receiver-dryer is integrated with the expansion valve, and various piping and valves are arranged within the available spaces between other system components, maximizing space utilization while maintaining assembly simplicity.
3Device complexity
If air-cooled condenser is used to avoid additional apparatus, then device complexity is reduced, but heat exchange efficiency decreases and condenser size increases
Solution Approach 1:
The air conditioning condenser is merged with the engine cooler to form an integrated heat exchange system. This allows the condenser to utilize the engine coolant circulation infrastructure without requiring a separate air-cooled condenser assembly, thereby reducing overall system complexity while maintaining compact dimensions through shared thermal management functions.
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 provides a space-saving, cost-effective, and easily integratable air conditioning module for electric vehicles, reducing assembly complexity and refrigerant charging requirements while enhancing heat exchange efficiency and safety.
Implementation Method 1
a condenser region for condensing the refrigerant is formed as a heat exchanging surface
Implementation Method 2
condenser region for condensing the refrigerant
Implementation Method 3
an excess cooling region for supercooling the liquid refrigerant is formed as a heat exchanging surface
Implementation Method 4
excess cooling region for supercooling the liquid refrigerant
Implementation Method 5
formed as an integrated plate heat exchanger having the condenser region, the excess cooling region, and the high-pressure-refrigerant collector region, and having insulation parts between heat exchanger regions
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
The present disclosure relates to a compact heat exchanger unit 1 within an air conditioning apparatus for a vehicle, and a condenser region 6 for the condensation of refrigerant is formed as a heat exchanging surface, and a high-pressure-refrigerant collector region 5 as a refrigerant collector is formed in the integrated form as a plate packet of a heat exchanger within a plate heat exchanger.