Alternating Plate Heat Exchanger for Pressure-Isolated Heat Transfer
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Solution Overview
Problem
Existing thermal management systems in electric vehicles face inefficiencies in heat transfer between high-pressure and low-pressure fluids in heat exchangers, leading to suboptimal performance and energy consumption.
Innovation Solution
A heat exchanger design with alternatingly stacked plates that create specific fluid communication and isolation spaces between high-pressure and low-pressure openings, utilizing turbulators and lips to enhance heat transfer and fluid flow management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional thermal management systems use conventional heat exchanger designs, then the system structure is simple, but heat transfer efficiency between high-pressure and low-pressure fluids is insufficient
Solution Approach 1:
The heat exchanger is divided into multiple plates with different configurations (first group and second group of plates), where each plate type has specific opening arrangements optimized for different fluid pathways. This segmentation allows simultaneous optimization of heat transfer efficiency and fluid management without requiring a completely complex redesign of the entire system.
Solution Approach 2:
The patent implements nested fluid pathways where first spaces and second spaces are formed between alternating plates, creating interconnected but isolated fluid channels. The first spaces provide fluid communication for low-pressure fluid while the second spaces provide fluid communication for high-pressure fluid, with each space nested within the multi-plate structure to achieve efficient heat transfer between pressure levels.
2Loss of energy
If multiple low-pressure inlets are used to improve fluid flow distribution, then heat transfer efficiency improves, but the risk of fluid mixing between different pressure levels increases
Solution Approach 1:
The plate structure is segmented into first group plates and second group plates with different opening configurations. First group plates have openings arranged to channel low-pressure fluid through first spaces, while second group plates have openings arranged to channel high-pressure fluid through second spaces. This segmentation ensures that multiple low-pressure inlets can be used for improved heat transfer without compromising fluid isolation.
Solution Approach 2:
Different regions of the plates have different opening arrangements and space configurations tailored to specific fluid pathways. The local structure of each plate type is optimized for its specific function (low-pressure or high-pressure fluid management), allowing efficient heat transfer while maintaining strict fluid isolation through locally adapted opening patterns and space formations.
3Loss of energy
If plates are alternatingly stacked to create separate fluid spaces, then heat transfer efficiency improves, but manufacturing complexity increases
Solution Approach 1:
The heat exchanger uses two types of plates (first group and second group) that can be manufactured using standard plate fabrication processes. Each plate type has a specific opening configuration that, when alternatingly stacked, creates the desired fluid spaces. This segmentation into standardized plate types simplifies manufacturing compared to creating entirely unique multi-chamber plates, as each plate type can be produced independently and then assembled through simple alternating stacking.
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
Enhances heat transfer efficiency between high-pressure and low-pressure fluids, improving the overall performance and energy efficiency of thermal management systems in electric vehicles.
Implementation Method 1
The first group of plates and the second group of plates are configured to allow the high-pressure fluid to transfer heat to the low-pressure fluid
Data Source
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AI summary
A heat exchanger has a first low-pressure inlet, a second low-pressure inlet, a low-pressure outlet, a high-pressure inlet, a high-pressure outlet, and a plurality of plates. Each plate in the plurality of plates has a first low-pressure opening fluidly connected to the first low-pressure inlet, a second low-pressure opening fluidly connected to the second low-pressure inlet, a third low-pressure opening fluidly connected to the low-pressure outlet, a first high-pressure opening fluidly connected to the high-pressure inlet, and a second high-pressure opening fluidly connected to the high-pressure outlet. The plurality of plates includes a first group of plates and a second group of plates. The first group of plates are alternatingly stacked with the second group of plates. The first group of plates and the second group of plates are configured to allow the high-pressure fluid to transfer heat to the low-pressure fluid.