Overlapping Heat Exchange Row Design for Compact HVAC Inner Condensers
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Solution Overview
Problem
Existing HVAC systems in electric vehicles face challenges in achieving a compact design for inner condensers in heat pump systems.
Innovation Solution
A heat exchanger design featuring overlapping first and second heat exchange rows with fluid connection elements, such as monolithic plugs or elbows, connecting distributors to reduce space requirements and enhance compactness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional heat exchanger designs are used, then manufacturing and assembly are simpler, but the heat exchanger occupies more space and is less compact
Solution Approach 1:
The fluid connection element is inserted into the distributors like a nested structure, with the connection element fitting inside the distributor bodies. This nesting approach allows multiple functional elements to occupy overlapping spatial volumes, reducing the overall heat exchanger volume while maintaining structural integrity and fluid flow pathways.
Solution Approach 2:
The patent transitions from traditional planar heat exchanger layouts to a three-dimensional overlapping row configuration. The first and second heat exchange rows are positioned in different spatial planes and overlap with each other, utilizing vertical and depth dimensions to reduce the horizontal footprint of the heat exchanger.
2Volume of moving object
If heat exchange rows are arranged in overlapping configuration, then space utilization is improved, but manufacturing and assembly become more difficult
Solution Approach 1:
The heat exchanger is divided into modular segments including first and second heat exchange rows, distributors, and fluid connection elements. Each segment can be manufactured separately using standardized processes, then assembled by inserting connection elements into distributors. This segmentation reduces manufacturing complexity despite the three-dimensional overlapping configuration.
Solution Approach 2:
The fluid connection element serves as an intermediary component that simplifies the connection between distributors in overlapping heat exchange rows. Rather than requiring complex welding or threading operations, the connection element provides a standardized insertion interface that facilitates easier assembly while enabling the compact overlapping arrangement.
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 solution provides a compact and efficient heat exchanger structure that optimizes space utilization while maintaining effective heat transfer performance.
Implementation Method 1
a plurality of parallel, coplanar tubes (13) interconnecting the first distributor (11) and the second distributor (12)
Implementation Method 2
Heat transfer fluid/air heat exchanger
Data Source
Figure 1
Figure 2~4
Figure 5
AI summary
A heat exchanger comprises a first heat exchange row (10) and a second heat exchange row (20), and also comprises a fluid connection element (40‴) that connects a first row distributor (11) to a second row distributor (21). The fluid connection element is an element (40‴) which is fixedly connected at the top to ends (11e, 21e) of the first row distributor (11) and of the second row distributor (21) and in which a conduit (41‴) is formed that fluidically connects the first row distributor (11) to the second row distributor (21).