Plate Heat Exchanger with Coplanar Flat Tubes for Turbocharged Engine Cooling
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Solution Overview
Problem
Current charge air coolers in turbocharged engines are inefficient in reducing air temperature to achieve desired performance and are too large, necessitating a new generation with improved thermal and dimensional performance.
Innovation Solution
A plate heat exchanger with paired plates forming coplanar, parallel flat circulation tubes, where the air flow undergoes successive heat exchanges with two fluids, with optimized tube configurations and flow disruptors to enhance thermal efficiency and minimize neutral zones, allowing for improved air cooling and fluid heating performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional RAS is used to cool the compressed air, then the air temperature is reduced to less than 80°C, but the thermal performance is insufficient to achieve the desired engine performance
Solution Approach 1:
The heat exchanger is divided into multiple plates (at least three plates forming two external faces) with circulation channels arranged in series. This segmentation allows the air flow to undergo successive heat exchanges with multiple fluid circuits, progressively reducing temperature from over 200°C to below 80°C, thereby achieving the required thermal performance.
Solution Approach 2:
The patent introduces a multi-dimensional heat exchange architecture where circulation channels are arranged in series across multiple plates, creating a three-dimensional heat exchange path. This allows successive heat exchanges with multiple fluid circuits, significantly improving thermal efficiency compared to conventional two-dimensional heat exchangers.
2Reliability
If the RAS is designed to achieve adequate cooling performance, then the thermal exchange is sufficient, but the device becomes too large for compact vehicle installation
Solution Approach 1:
Multiple heat exchange circuits are nested within a compact plate structure. At least three plates form two external faces with circulation channels arranged in series, allowing multiple fluid circuits to be integrated in a compact configuration. This nested arrangement achieves sufficient cooling performance while minimizing the overall device volume for vehicle installation.
Solution Approach 2:
The patent utilizes a multi-plate configuration with channels arranged in series across three or more plates, transforming the heat exchange from a two-dimensional surface process to a three-dimensional volumetric process. This enables adequate cooling performance within a compact footprint suitable for vehicle constraints.
3Reliability
If the circulation channels are arranged to optimize heat exchange, then thermal efficiency is improved, but the structure becomes more complex
Solution Approach 1:
The heat exchanger is segmented into multiple plates with circulation channels arranged in series, creating modular units that can be assembled by stacking. This segmentation optimizes heat exchange efficiency while maintaining manufacturing simplicity through standardized plate designs and straightforward assembly procedures.
Solution Approach 2:
The plate structure serves multiple functions simultaneously: it forms separation walls between fluid circuits, provides circulation channels for multiple fluids, and creates the overall structural framework. This multi-functionality reduces the number of separate components needed, simplifying the overall structure while optimizing thermal efficiency.
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 significantly enhances thermal and dimensional performance, effectively reducing air temperature and optimizing heat exchanges, making it suitable for turbocharged engines while minimizing space and improving fluid circulation efficiency.
Implementation Method 1
the air flow is therefore first in heat exchange with the first tube and then in heat exchange with the second tube
Implementation Method 2
a first fluid circulates between a first inlet orifice and a first outlet orifice... a second fluid circulates between a second inlet orifice and a second outlet orifice
Data Source
Figure 1~2
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AI summary
The invention relates to a plate heat exchanger (14) forming, between the plates (28) thereof, a first flat flow tube (56), into which a first fluid (20) flows between a first inlet (52) and a first outlet (54), and a second flat flow tube (58), in which a second fluid (24) flows between a second inlet (38) and a second outlet (40). Both flat tubes (56, 58) form parallel arms that extend in a longitudinal direction (L) perpendicular to a transverse air flow (12) that passes through the heat exchanger (14), the first tube (56) being upstream in the air flow (12), and the second tube (58) being downstream.