Integrated plate-type heat exchanger
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Solution Overview
Problem
The complexity of the assembly process and performance loss due to pressure drops in coolant and refrigerant flows in water-cooled heat exchangers for electric vehicles, which increases the length of piping and complexity of the assembly process.
Innovation Solution
An integrated plate-type heat exchanger with a connecting plate unit that forms multiple refrigerant pathways between the condenser, internal heat exchanger, chiller, and expansion valve, reducing the need for lengthy piping and simplifying the assembly process while minimizing pressure drops.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate water-cooled heat exchangers (chiller, condenser, IHX) are used with connecting pipes and valves, then each component can perform its specific thermal management function, but the assembly process becomes more complex and pressure drops occur in coolant and refrigerant flows
Solution Approach 1:
The patent combines multiple separate heat exchangers (chiller, condenser, internal heat exchanger) into a single integrated plate-type heat exchanger unit. The connecting plate unit integrates refrigerant flow paths and coolant flow paths within a unified structure, eliminating the need for external pipes and valves to connect separate components. This merging reduces assembly complexity while maintaining all required thermal management functions through internally integrated heat exchange plates and flow channels.
2Adaptability or versatility
If separate water-cooled heat exchangers are used with connecting pipes, then each component can perform its specific function, but the length of piping increases and pressure drops occur in coolant and refrigerant flows
Solution Approach 1:
The integrating of multiple heat exchangers into a single unit with internally connected flow paths eliminates external piping, thereby removing the source of pressure drops that would occur in connected separate components.
Solution Approach 2:
The connecting plate unit acts as an intermediary structure that provides direct, integrated flow paths between heat exchange sections. By serving as a built-in mediator within the unified plate structure, it eliminates the need for external pipes that would cause pressure losses, allowing smooth transition of refrigerant and coolant between functional sections.
3Adaptability or versatility
If separate water-cooled heat exchangers are used with connecting pipes and valves, then each component can perform its specific function, but the overall system becomes less compact and heavier
Solution Approach 1:
The patent merges multiple heat exchangers into a single integrated unit with shared plates and internally integrated flow paths, eliminating external pipes, valves, and mounting hardware. This consolidation reduces the total material required and creates a more compact assembly, directly reducing system weight while maintaining all thermal management functions within the unified structure.
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
This configuration reduces the length of piping and assembly complexity, and decreases pressure drops caused by refrigerant and coolant flows, enhancing the efficiency and compactness of the thermal management system.
Implementation Method 1
a condenser configured to condense refrigerant by heat exchange between first coolant and the refrigerant
Implementation Method 2
a condenser configured to condense refrigerant by heat exchange between first coolant and the refrigerant
Implementation Method 3
a chiller configured to cool second coolant by heat exchange between the refrigerant passing through the condenser and the second coolant
Implementation Method 4
an internal heat exchanger configured to facilitate heat exchange between the refrigerant coming from the condenser and the refrigerant coming from the chiller
Data Source
AI summary
An integrated plate-type heat exchanger includes: a condenser configured to condense refrigerant by heat exchange between first coolant and the refrigerant; a chiller configured to cool second coolant by heat exchange between the refrigerant passing through the condenser and the second coolant; an internal heat exchanger configured to facilitate heat exchange between the refrigerant coming from the condenser and the refrigerant coming from the chiller; an expansion valve configured to expand the refrigerant discharged from the internal heat exchanger; a connecting plate unit positioned between the internal heat exchanger and the chiller to form a flow path for the refrigerant; and one or more refrigerant outlets to discharge the refrigerant from the connecting plate unit. The connecting plate unit comprises first and second connecting plates positioned to adhere to each other. The first and second connecting plates include one or more through holes for movements of the refrigerant between the internal heat exchanger, the chiller, the expansion valve, and the refrigerant discharge port, and one or more refrigerant spaces for movement of the refrigerant between the first and second connecting plates.