Integrated stacked heat exchangers

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Solution Overview

Problem

Existing vehicle refrigeration systems face challenges in efficiently managing heat transfer for both HVAC systems and other vehicle components, such as batteries, which require optimal temperature conditions for performance and longevity.

Innovation Solution

The proposed vehicle refrigeration system includes a stacked arrangement of first and second chillers, each with refrigerant and coolant fluid paths, and a refrigerant control block that facilitates the flow of refrigerant between the chillers, allowing for independent control of coolant exit temperatures and efficient heat exchange between refrigerant and coolant.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple separate chillers are used for different vehicle components, then each component can be cooled independently, but the system complexity and number of plumbing connections increases

Engineering Contradiction:

Improveindependent cooling controlVSAvoidplumbing connections

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines multiple chiller functions into a single integrated chiller unit with multiple evaporators. The first evaporator serves the HVAC system while the second evaporator serves additional vehicle components. This merging approach maintains independent cooling control for different components through separate expansion valves and refrigerant flow paths, while simultaneously reducing the overall number of plumbing connections and system components compared to using separate chiller units for each application.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated chiller is designed as a multi-functional device that can simultaneously provide cooling to multiple different vehicle systems. The single chiller unit incorporates multiple evaporators that can independently serve the HVAC system and other vehicle components, allowing one universal device to perform multiple cooling functions that would traditionally require separate specialized chillers for each application.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If traditional separate chiller systems are used, then each system can be optimized for its specific function, but assembly time and manufacturing costs increase

Engineering Contradiction:

Improvefunction-specific optimizationVSAvoidassembly time

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent merges multiple chiller assemblies into a single integrated unit with common components such as the compressor, condenser, and refrigerant circulation system. This consolidation reduces the number of separate assemblies that need to be manufactured and installed, thereby reducing assembly time and manufacturing complexity while maintaining the ability to optimize each evaporator circuit for its specific cooling application through dedicated expansion valves and flow control mechanisms.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If multiple separate chiller systems are implemented, then redundant cooling capacity is provided, but the number of potential leak paths increases

Engineering Contradiction:

Improvecooling redundancyVSAvoidleak paths

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The integrated chiller design consolidates multiple refrigerant circulation systems into a single unified system with one compressor, one condenser, and shared refrigerant lines. This merging approach maintains cooling redundancy through multiple evaporators that can operate independently or together, while simultaneously reducing the total number of refrigerant connections and potential leak paths compared to having completely separate chiller systems for different vehicle components.

Inventive Principle:

Principle #5Merging (Combining)

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 plumbing connections, assembly time, and costs while minimizing leak paths, achieving efficient heat management for both HVAC systems and other vehicle components, thereby enhancing performance and longevity.

Implementation Method 1

efficient heat exchange between refrigerant and coolant

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS12330473B2Integrated stacked heat exchangers

Publication Date: 2025.06.17 AIR INT

AI summary

A vehicle refrigeration system according includes a first chiller including a refrigerant fluid path and a coolant fluid path. A second chiller includes a refrigerant fluid path, a coolant fluid path, a first chiller coolant inlet, a second chiller coolant inlet, a first chiller coolant outlet, and a second chiller coolant outlet. A refrigerant control block includes outer walls providing openings in fluid communication with control block refrigerant fluid paths. The openings include a first chiller control block outlet and a second chiller control block outlet. The first chiller receives refrigerant flowing out of the first chiller control block outlet and into the first chiller refrigerant fluid path. The second chiller receives refrigerant flowing out of the second chiller control block outlet, through the first chiller, and into the second chiller refrigerant fluid path.