Internal heat exchanger
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Solution Overview
Problem
Current air conditioning systems for vehicles, including internal heat exchangers, face inefficiencies and high manufacturing costs, particularly in hybrid vehicles, leading to increased energy consumption and pollutant emissions, with existing designs not adequately addressing the need for improved performance without increased dimensions.
Innovation Solution
The internal heat exchanger features a prismatic intermediate portion with multiple ducts of varying diameters and shapes, connected by end portions with mechanical coupling and sealing means, allowing for efficient counter-current fluid flow and a high heat exchange area-to-volume ratio within compact dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional heat exchanger designs are used, then manufacturing process is costly and manufacturing precision is difficult to achieve, but the patent achieves simplified manufacturing with improved precision through extrusion and assembly
Solution Approach 1:
The heat exchanger is divided into three separate components: a first body, a second body, and an intermediate element. These segments are manufactured independently using extrusion processes, allowing each to be optimized for its specific manufacturing requirements while maintaining overall geometric precision through controlled assembly with sealing elements.
Solution Approach 2:
The patent employs extrusion manufacturing parameters to create the intermediate element with specific geometric features including channels and sealing surfaces. By controlling extrusion parameters, the design achieves consistent dimensional accuracy and surface quality without requiring complex post-processing operations.
2Area of stationary object
If conventional heat exchanger designs are used, then the area of heat exchange to volume ratio is low, but the patent increases this ratio through compact intermediate element design
Solution Approach 1:
The intermediate element introduces a complex three-dimensional network of channels and passages that maximize heat exchange surface area within a compact volume. The design utilizes multi-directional channel arrangements and varying cross-sections to achieve high surface-to-volume ratios without increasing overall exchanger dimensions.
3Use of energy by moving object
If hybrid vehicles use current air conditioning systems, then energy consumption increases, but the patent reduces energy consumption through improved heat exchange efficiency
Solution Approach 1:
The intermediate element features locally optimized channel geometries with varying cross-sections, wall thicknesses, and flow path configurations tailored to specific thermal and fluid dynamic requirements at different locations. This local optimization enhances heat transfer coefficients and reduces pressure losses, improving overall system efficiency and reducing energy consumption.
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 design achieves efficient heat exchange with a high area-to-volume ratio, maintaining performance while reducing size and manufacturing costs, ensuring effective cooling with a simple and cost-effective construction.
Implementation Method 1
The intermediate portion 2 is prismatic in shape having a development along a longitudinal axis A and having a substantially flat section... efficient heat exchange with a high area-to-volume ratio
Implementation Method 2
allowing for efficient counter-current fluid flow and a high heat exchange area-to-volume ratio within compact dimensions
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
An internal heat exchanger (1) for an air conditioning system of a vehicle comprising an intermediate portion (2) and two end portions (3), each of the end portions (3) comprises a first opening (20) for the passage of a first conditioning fluid inside the internal heat exchanger (1) and a second opening (21) for the passage of a second conditioning fluid inside the heat exchanger (1). The intermediate portion (2) being hollow and defining an inner volume (9), the intermediate portion (2) further comprising a plurality of ducts (10) housed inside the inner volume (9) extending between the end portions (3), the first opening (20) being fluidically connected via respective ducts (22) to each of the ducts (10), the second opening (21) being fluidically connected to the inner volume (9) via an individual duct (25).