Manifold fluid module integrated with gas-liquid separator
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Solution Overview
Problem
Current electric vehicle heat pump systems face issues with increased costs and reduced workability due to separate components like valves, gas-liquid separators, and heat exchangers connected by piping, leading to packaging and assembly challenges.
Innovation Solution
A manifold fluid module integrating a gas-liquid separator, heat exchangers, and valves into a single unit, with a manifold plate and integral gas-liquid separator, reducing the need for separate fittings and optimizing component placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If components (valves, gas-liquid separators, heat exchangers) are connected by piping with separate fittings, then each component can be manufactured independently, but the device complexity and assembly workability deteriorate
Solution Approach 1:
The patent merges multiple components (manifold, gas-liquid separator, heat exchangers, valves) into a single integrated manifold assembly. The manifold body is designed with internal fluid passages that directly connect to integrated components, eliminating the need for external piping and fittings. This consolidation reduces device complexity while maintaining independent manufacturability of the integrated unit.
Solution Approach 2:
The manifold assembly serves multiple functions simultaneously: it acts as a fluid distribution manifold, a gas-liquid separator, a heat exchanger housing, and a valve mounting structure. This multi-functionality reduces the overall number of separate components needed in the heat pump system, simplifying the device structure while preserving manufacturing flexibility.
2Ease of repair
If components are connected by piping with separate fittings, then component replacement and maintenance are easier, but assembly workability and packaging efficiency deteriorate
Solution Approach 1:
By integrating components into a single manifold assembly, the patent improves assembly workability and packaging efficiency. The integrated design eliminates numerous piping connections and fittings, reducing assembly steps and improving manufacturability. Component replacement is facilitated through modular design of the integrated assembly, allowing the entire manifold unit to be replaced as a single module.
3Ease of manufacture
If gas-liquid separator is integrated with manifold plate, then manufacturing costs and assembly complexity are reduced, but manufacturing precision requirements increase
Solution Approach 1:
The gas-liquid separator is integrally formed with the manifold plate as a single component. This integration eliminates the need for separate fittings and connectors, reducing assembly complexity and manufacturing costs. The integral design ensures precise alignment and sealing between the separator and manifold passages, meeting the increased manufacturing precision requirements through unified manufacturing processes.
4Area of stationary object
If multiple components are integrated into a single unit, then packaging space and assembly workability are improved, but device complexity in design increases
Solution Approach 1:
The patent integrates the manifold, gas-liquid separator, heat exchangers, and valves into a compact single unit, significantly reducing packaging space and improving spatial efficiency. The integrated design consolidates multiple component functions into a unified structure with internal fluid passages, simplifying the overall system layout while reducing the total volume required for installation and packaging.
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 integration reduces costs and improves workability by minimizing manufacturing labor and assembly complexity, enhancing spatial efficiency and fluid flow management.
Implementation Method 1
a gas-liquid separator at least partially integrally formed with the manifold plate to create an inflow space for the first fluid expanded by the first expansion valve and to separate the first fluid into gas and liquid phases
Implementation Method 2
a heat exchanger coupled to the manifold plate for heat exchange between the first fluid and a second fluid
Implementation Method 3
a first expansion valve coupled to the manifold plate and configured to block the flow of a first fluid or expand the first fluid based on air conditioning mode
Data Source
AI summary
An embodiment relates to a manifold fluid module integrated with a gas-liquid separator. The manifold fluid module integrated with the gas-liquid separator according to the embodiment may include a manifold plate including a fluid passage formed internally, a heat exchanger coupled to the manifold plate for heat exchange between a first fluid and a second fluid, a first expansion valve coupled to the manifold plate and configured to block the flow of the first fluid or expand the first fluid based on air conditioning mode, and a gas-liquid separator at least partially integrally formed with the manifold plate to create an inflow space for the first fluid expanded by the first expansion valve and to separate the first fluid into gas and liquid phases.