Plate Heat Exchanger Brake Resistor With Low Pressure Loss Cooling
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Solution Overview
Problem
Existing liquid-cooled braking resistors face challenges with large space requirements, significant pressure loss, and inefficient heat transfer, while requiring high tensile strength and compressive stability, especially in compact and sound-emission-limited applications.
Innovation Solution
A compact liquid-cooled system using shaped metal sheets with an electrically insulating layer and a conductive device, where coolant flows over one face and the sheets are joined to form a modular structure with a large heat-transfer surface area, minimizing internal pressure loss and enhancing heat transfer efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the active element is insulated in a tubular heating body with meandering coolant flow, then heat transfer is achieved, but pressure loss increases significantly
Solution Approach 1:
The patent divides the cooling system into multiple parallel flow channels instead of a single meandering path. The coolant is distributed across several channels that flow simultaneously, reducing resistance and pressure loss while maintaining effective heat transfer from the resistor element to the coolant.
Solution Approach 2:
The patent transitions from a one-dimensional meandering flow path to a multi-dimensional parallel channel structure. By arranging multiple flow channels in parallel and distributing coolant across them, the system reduces flow path length and resistance while increasing the effective heat transfer surface area.
2Volume of stationary object
If air-cooled braking resistors are used, then cooling is achieved, but installation space increases
Solution Approach 1:
The patent employs liquid cooling instead of air cooling, utilizing the superior heat capacity and thermal conductivity of liquid coolant. This allows for more efficient heat removal from the resistor in a compact volume, eliminating the need for large ventilation systems and reducing overall installation space.
Solution Approach 2:
The patent changes the cooling medium from gas (air) to liquid, fundamentally altering the heat transfer parameters. Liquid coolant provides higher heat capacity and thermal conductivity, enabling effective cooling in a smaller volume and improving overall cooling efficiency.
3Reliability
If elastic pressing means with springs are used to press the flat layer against the resistor, then contact is maintained, but device complexity increases
Solution Approach 1:
The patent removes the complex elastic pressing means with springs from the design. Instead, it uses a simplified rigid or semi-rigid support structure that maintains adequate contact between the flat layer and the resistor element, eliminating unnecessary mechanical complexity while preserving functional reliability.
Solution Approach 2:
The patent employs a flexible flat layer that can conform to the resistor surface and maintain contact through its own flexibility rather than requiring external spring pressure. This thin film approach maintains reliable thermal and electrical contact while significantly reducing structural complexity.
4Area of stationary object
If a block structure with hollow space is used, then resistor support is achieved, but heat transfer surface area is limited
Solution Approach 1:
The patent transitions from a three-dimensional block structure with internal hollow spaces to a planar or layered structure that maximizes heat transfer surface area in two dimensions. This approach increases the effective contact area between the resistor, flat layer, and coolant while simplifying the overall structural design.
Solution Approach 2:
The patent divides the heat transfer function into multiple separate layers (resistor element, flat layer, coolant channels) rather than using a monolithic block structure. This segmentation allows each layer to be optimized for its specific function while collectively providing large heat transfer surface area with reduced structural 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 solution achieves a compact design with reduced volume and weight, improved heat transfer efficiency, and scalability, while maintaining high tensile strength and compressive stability, thus addressing the limitations of prior art.
Implementation Method 1
the electrically insulating layer has very good heat conductivity in order that the flow of heat generated by the electrically conductive device can be effectively conveyed to the shaped metal sheet
Implementation Method 2
a second face, the latter serving as a surface over which coolant can flow
Data Source
AI summary
A shaped metal sheet and a liquid-cooled resistor, which is made up of a plurality of shaped metal sheets, are provided. The shaped metal sheets have a first side which is coated with an electrically insulating layer, an electrically conductive device being applied to the electrically insulating layer or embedded therein, and the shaped metal sheets having a second side through which coolant can flow. By connection of a plurality of shaped metal sheets, a coolable resistor is produced, which is very compact, space-saving and scalable.