Modular Heat Exchanger Manifolds for High-Pressure Refrigerant Systems
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Solution Overview
Problem
Conventional heat exchangers are inefficient and unable to withstand high fluid pressures, particularly for refrigerants like R744 (CO2) and R290, which require higher mechanical resistance and efficient operation up to 260 bar on the low-pressure side and 360 bar on the high-pressure side.
Innovation Solution
A novel internal heat exchanger design featuring a first and second manifold with U-path fluid flow, arranged tubes, and spacers to enhance mechanical strength and heat exchange efficiency, capable of handling high fluid pressures while maintaining efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional heat exchanger design is used, then manufacturing cost is low and structure is simple, but mechanical resistance is insufficient for high-pressure fluids
Solution Approach 1:
The heat exchanger is divided into multiple modules, each containing a specific number of tubes (e.g., 5 tubes per module). This modular segmentation allows the system to achieve the required mechanical strength for high-pressure applications while maintaining a systematic and manageable structure that does not excessively increase complexity.
Solution Approach 2:
The patent employs composite construction methods where tubes are connected to plates using brazing or welding, creating a composite structure that combines the strength of metal joints with the heat exchange efficiency of the tube-plate configuration. This composite approach enhances mechanical resistance to withstand high-pressure fluids up to 360 bar while maintaining structural integrity.
2Productivity
If heat exchanger is designed for high-pressure efficiency, then heat exchange efficiency is improved, but mechanical resistance requirements increase
Solution Approach 1:
The heat exchanger design implements local quality optimization by configuring tubes in specific patterns (e.g., U-shaped tubes connecting opposite sides of plates) and arranging them in modules with specific spacing. This localized structural optimization enhances heat exchange efficiency in critical areas while the overall modular design ensures the system can withstand high pressures up to 360 bar without requiring excessive strength throughout the entire 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
The design effectively withstands high fluid pressures and ensures efficient heat exchange between low and high-pressure refrigerants, improving the performance of cooling systems without sacrificing mechanical resistance.
Implementation Method 1
a heat exchanger core arranged between the pair of manifolds. The heat exchanger core is formed of a plurality of flat tubes (hereinafter, also referred to as tubes for simplicity) and fins arranged between outer surfaces of the adjacent tubes
Implementation Method 2
One of the fluid/coolants flows from the first manifold to the second manifold through the plurality of tubes and the other fluid/air flows around and in a space between the tubes to enable heat exchange between the fluids
Data Source
Figure 1
Figure 2
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AI summary
A heat exchanger (100) for a motor vehicle is disclosed. The heat exchanger (100) comprises a first manifold (102), a second manifold (104), the first manifold (102) and the second manifold (104) being configured for circulating at least one of a first fluid and a second fluid, and a plurality of tubes (112, 114) fluidically connected between the first manifold (102) and the second manifold (104). At least one of the first manifold (102) and the second manifold (104) comprises at least one of a first canal (106) and a second canal (108) for ingress of at least one of the first fluid and the second fluid, and at least one of a third canal (110) and a fourth canal (117) for egress of at least one of the first fluid and the second fluid.