Plate Heat Exchanger Layout for Uniform Battery Pack Cooling
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Solution Overview
Problem
Existing heat exchanger systems for thermal management of electrical and electronic elements in electric vehicles suffer from non-uniform cooling, high thermal resistance, and significant pressure drops, which limit the performance and lifespan of components.
Innovation Solution
The heat exchanger is integrated directly into the battery pack and immersed in a dielectric fluid, eliminating the need for a separate outlet header and reducing pressure drops by incorporating openings in the exchanger canals, thereby improving fluid distribution and thermal performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a plate-type heat exchanger is used for thermal management, then thermal performance is improved, but pressure drops increase significantly
Solution Approach 1:
The outlet header is extracted and removed from the heat exchanger structure. Instead of using a centralized outlet header that creates irregular pressure drops, the patent opens the canals directly to the exterior at multiple points along the plates, eliminating the header component and its associated flow resistance
Solution Approach 2:
The single outlet function is segmented into multiple outlet points distributed along the lateral walls of the heat exchanger. This segmentation of the outlet function into multiple locations creates more uniform flow distribution and reduces pressure drops compared to a centralized outlet
2Temperature
If a plate-type heat exchanger with headers is used, then heat exchange capability is improved, but fluid distribution uniformity deteriorates
Solution Approach 1:
The headers that cause non-uniform fluid distribution are extracted and removed from the system. The canals are opened directly along the lateral walls, eliminating the distribution issues associated with header geometry and creating more uniform flow patterns
Solution Approach 2:
Instead of uniform outlets distributed along the entire length, the patent implements localized outlet openings at specific positions along the lateral walls. This local quality approach allows optimization of flow distribution at different sections of the heat exchanger
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
This solution enhances the thermal management system by reducing pressure drops, improving fluid distribution, and increasing the efficiency and uniformity of cooling, thereby extending the life and performance of electrical and electronic components.
Implementation Method 1
heat exchanger (10) intended for the exchange of heat between a first fluid (4) and a second fluid (6)
Implementation Method 2
the plate being in contact with the elements that are to be cooled
Data Source
AI summary
A heat exchanger is disclosed. The heat exchanger includes a stack of plates extending between an upper end plate and a lower end plate. The lower end plate includes four lateral walls extending in the direction of the stack. The stack of plates forms an alternation of first canals for the first fluid and of second canals for the second fluid. The heat exchanger includes a first inlet and at least two first outlets which are fluidically connected to the first canals. The upper end plate includes the first inlet. At least one of the lateral walls includes the at least two first outlets.