Multi-Circuit Heat Exchanger for High-Pressure Refrigerant Integration
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Solution Overview
Problem
Conventional heat exchangers fail to efficiently handle high-pressure fluids like R744 (CO2) or R290 (propane), face design constraints due to mechanical resistance requirements, and lack efficient packaging solutions, especially in integrating multiple heat exchanger types within a single unit, while also struggling with pressure drop and mass production efficiency.
Innovation Solution
A heat exchanger design featuring alternating arrangements of first, second, and third tubes, with a housing encapsulating some tubes to facilitate heat exchange between different fluids, including a housing with parallel walls for insulation and a U-flow pattern, along with spacers and fins for enhanced efficiency and structural support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional heat exchanger designs are used with high-pressure fluids, then mechanical resistance requirements increase, but heat exchange efficiency decreases
Solution Approach 1:
The heat exchanger is divided into multiple independent circuits (first circuit with first tubes, second circuit with second tubes, third circuit with third tubes) that can handle different pressure levels separately. This segmentation allows each circuit to be optimized for its specific pressure range, maintaining mechanical resistance where needed while preserving heat exchange efficiency in other circuits.
Solution Approach 2:
The heat exchanger integrates multiple functions into a single device: it serves as a high-pressure heat exchanger for R744, a low-pressure heat exchanger for refrigerant, and a water-to-refrigerant heat exchanger, all within one unified structure. This multi-functionality eliminates the need for separate heat exchangers while maintaining performance across different pressure regimes.
2Volume of moving object
If multiple heat exchanger types are integrated into a single unit, then packaging space is reduced, but design complexity increases
Solution Approach 1:
Multiple heat exchanger functions are merged into a single integrated unit with shared manifolds and tube structures. The first, second, and third circuits are combined within one heat exchanger body, reducing the total packaging volume while using standardized components that simplify the overall design despite the multi-functional requirements.
Solution Approach 2:
The heat exchanger utilizes three-dimensional spatial arrangement with tubes arranged in alternating patterns (first tubes, second tubes, third tubes) that stack vertically and horizontally. This dimensional organization allows multiple circuits to coexist in compact space without excessive design complexity, as the alternating arrangement provides clear structural patterns for manufacturing.
3Reliability
If the number of tubes in the IHX section is reduced to control efficiency, then pressure drop increases, but mass production adaptability decreases
Solution Approach 1:
The heat exchanger design allows for dynamic adjustment of the number and arrangement of tubes in the internal heat exchanger section. The alternating pattern of first, second, and third tubes can be configured in different ratios (e.g., 2:1, 3:2) depending on the desired efficiency level, while maintaining a modular structure that facilitates mass production through standardized manufacturing processes.
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 up to 260 bar on the low-pressure side and 360 bar on the high-pressure side, optimizing heat exchange efficiency and reducing packaging complexity, while maintaining performance across multiple heat exchanger functions.
Implementation Method 1
a plurality of tubes fluidically connected between the first manifold and the second manifold, the tubes being configured to enable circulation of at least one of a first fluid and a second fluid between the first manifold and the second manifold
Implementation Method 2
heat exchange/transfer between two or more fluids/media
Implementation Method 3
the housing being configured to at least partially encapsulate the first tubes and at least the second tubes to enable circulation of at least a third fluid
Data Source
Figure 1
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AI summary
The invention concerns, inter alia, a heat exchanger (100) for a motor vehicle comprising: a first manifold (102); a second manifold (104) configured spaced apart from the first manifold (102); and a plurality of tubes (112, 114, 115) fluidically connected between the first manifold (102) and the second manifold (104), the tubes (112, 114, 115) being configured to enable circulation of at least one of a first fluid (HP) and a second fluid (LP) between the first manifold (102) and the second manifold (104); wherein the plurality of tubes (112, 114, 115) comprises one or more sets of first tubes (112) and one or more sets of second tubes (114), wherein the one or more sets of first tubes (112) and the one or more sets of second tubes (114) are arranged one above another in an alternate manner in at least one row such that at least a portion of neighboring tubes of the corresponding set of first tubes (112) and the set of second tubes (114) abut each other; wherein the plurality of tubes (112, 114, 115) comprises one or more sets of third tubes (115), the third tubes (115) being arranged one above another in an alternate manner in at least one row such that at least a portion of neighboring tubes of the corresponding set of second tubes (114) and the set of third tubes (115) abut with each other, wherein the heat exchanger (1) further comprises a housing (300), the housing (300) being configured to at least partially encapsulate the first tubes (112) and at least the second tubes (114) to enable circulation of at least a third fluid (COOL).