Modular Refrigerant Layout for Low-Pressure-Loss Heat Management
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Solution Overview
Problem
The existing heat management systems for electric vehicles face challenges with complex assembly processes and significant pressure drops in refrigerant pipes due to long connections between components, leading to performance losses.
Innovation Solution
A modularized heat management system is designed with a configuration that includes a first heat exchanger, expansion valves, a second heat exchanger, an accumulator, and an internal heat exchanger, where components are strategically positioned and connected to minimize pipe lengths and reduce pressure drops, with modularization improving assemblability and system performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If components are connected using long pipes to achieve system configuration, then the system can be assembled, but pressure drop of refrigerant increases causing performance loss
Solution Approach 1:
Multiple heat exchangers (evaporator, condenser, indoor heat exchanger, outdoor heat exchanger) and expansion valves are integrated into a single modular assembly connected by short internal passages. This merging of components eliminates the need for long external pipes, thereby reducing refrigerant pressure drop and improving system performance while maintaining complete system functionality.
2Ease of manufacture
If components are assembled separately with long connecting pipes, then assembly flexibility is maintained, but assembly process becomes complicated and difficult
Solution Approach 1:
The heat exchangers and expansion valves are pre-assembled into an integrated module with internal connections, transforming a complex multi-step assembly process into a simple module installation. This reduces assembly complexity while maintaining the flexibility to replace the entire module as a single unit.
Solution Approach 2:
The refrigeration system is divided into modular units that can be independently manufactured and tested, then assembled together. This segmentation allows each module to be optimized separately and simplifies the overall assembly process, making manufacturing easier while reducing system complexity.
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 modularized system reduces the distance between components, minimizing refrigerant pressure loss and enhancing system performance by optimizing the flow path of the heat exchange medium, thereby improving both assembly efficiency and cooling performance.
Implementation Method 1
a first heat exchanger heat-exchanging a heat exchange medium flowing thereinto from a compressor
Implementation Method 2
a first expansion valve expanding the heat exchange medium flowing thereinto from the first heat exchanger
Implementation Method 3
a second heat exchanger heat-exchanging the heat exchange medium flowing thereinto from the second expansion valve with a heat-generating component
Implementation Method 4
an internal heat exchanger heat-exchanging the heat exchange medium discharged from the condenser with a heat exchange medium discharged from an evaporator
Data Source
AI summary
The present invention relates to a heat management system having performance improved by reducing a distance between components constituting a refrigerant module and minimizing a pressure loss of a refrigerant, the heat management system including: a first heat exchanger heat-exchanging a heat exchange medium flowing thereinto from a compressor; a first expansion valve expanding the heat exchange medium flowing thereinto from the first heat exchanger and transferring the expanded heat exchange medium to a condenser; a second expansion valve expanding the heat exchange medium flowing thereinto from the condenser; a second heat exchanger heat-exchanging the heat exchange medium flowing thereinto from the second expansion valve with a heat-generating component; an accumulator storing the heat exchange medium flowing thereinto from the second heat exchanger; and an internal heat exchanger heat-exchanging the heat exchange medium discharged from the condenser with a heat exchange medium discharged from an evaporator.