Plate IHX Structure for Refrigerant Module Mounting
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Solution Overview
Problem
Existing internal heat exchanger assemblies in electric vehicles lack structural integrity and efficient component mounting solutions, leading to increased complexity and cost in refrigerant system design and operation.
Innovation Solution
A plate-type internal heat exchanger assembly with multiple layers, where at least three plates are joined to form separate compartments for high and low pressure fluids, providing structural support and heat transfer, and allowing for the mounting of refrigerant components on a flat external surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional extruded co-tube form IHX is used, then heat exchange function is provided, but structural integrity and component mounting capability are insufficient
Solution Approach 1:
The IHX assembly is designed to perform multiple functions simultaneously: heat exchange between high and low pressure fluids, structural support for mounting refrigerant components, and integration of multiple compartments. The plate structure serves both as a thermal transfer surface and as a mechanical framework, eliminating the need for separate structural supports and reducing overall system complexity.
Solution Approach 2:
The patent combines the IHX heat exchange function with structural support functions into a single integrated assembly. Multiple plates are joined to form both the heat exchange compartments and the mounting structure, merging previously separate components into one unified structure that reduces part count and assembly complexity.
2Adaptability or versatility
If separate structural supports are added for mounting components, then component mounting capability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The IHX assembly is designed with flat external surfaces on its plates that serve dual purposes: maintaining the structural integrity of the heat exchanger and providing mounting surfaces for refrigerant components. This eliminates the need for separate structural supports and allows direct mounting of components like accumulators, receivers, and flow control devices onto the IHX itself.
3Reliability
If multiple separate components are used for heat exchange and structural support, then functional performance is maintained, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The patent integrates multiple plates into a single assembled structure that performs both heat exchange and provides structural support. The plates are joined through welding or brazing to form a unified assembly that maintains reliable thermal management performance while reducing the number of separate components that need to be manufactured, sourced, and assembled.
Solution Approach 2:
The IHX is constructed from multiple individual plates that are joined together, allowing for modular manufacturing and assembly. Each plate can be fabricated separately and then joined to form the complete heat exchanger structure, enabling flexible manufacturing approaches and simplifying production while maintaining functional performance.
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 enhances structural integrity and reduces refrigerant line complexity by integrating a heat exchanger and structural member, effectively managing thermal conditions and component mounting within electric vehicles.
Implementation Method 1
The heat spreader plate forms a portion of the first and second chambers, such that the heat spreading plate conducts the heat transferred from the high pressure fluid to the low pressure fluid.
Implementation Method 2
The compartment or channel that contains the high pressure fluid is in thermal communication with the compartment or channel that contains the low pressure fluid, such that heat is transferred from the high pressure fluid to the low pressure fluid.
Data Source
AI summary
An internal heat exchanger (IHX) assembly for use in a vehicle includes at least three plates joined together to form two or more separate compartments or channels and at least one flat structure on an external surface of the IHX assembly. One compartment or channel contains a high pressure fluid and the other compartment or channel contains a low pressure fluid. The compartment or channel containing the high pressure fluid is in thermal communication with the compartment or channel containing the low pressure fluid, such that heat is transferred from the high pressure fluid to the low pressure fluid. The IHX assembly acts as a structural member in the vehicle upon which one or more refrigerant components are mounted onto the flat structure.