Process valve manifold and heat exchanger system
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Solution Overview
Problem
Existing process valve manifolds for heat exchanger systems in motor vehicles lack integrated thermal management and compact structure, leading to inefficiencies in heat distribution and consumption.
Innovation Solution
A process valve manifold with a 3/2-way valve and integrated control valves allows continuous variation of the heat transfer medium flow path between main and bypass outlets, eliminating the need for external pipes or modules, and includes throttle for pressure adjustment and secondary circuit connections for efficient heat distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional process valve manifolds are used without integrated thermal management, then external pipes and modules are required for heat distribution, but the system becomes more complex and occupies more space
Solution Approach 1:
The patent integrates multiple functions (process valve manifold, thermal management system, heat distribution circuits) into a single compact unit. The housing contains both the valve manifold and heat exchanger functions, eliminating the need for separate external pipes and modules while maintaining full thermal management capability
Solution Approach 2:
The process valve manifold is designed to perform multiple functions simultaneously: it serves as a valve control unit, a heat exchanger, and a distribution manifold. This multi-functionality allows the same component to handle both fluid control and thermal management, reducing overall system complexity
2Area of stationary object
If external pipes and modules are used for heat distribution, then thermal management flexibility is maintained, but spatial requirements increase
Solution Approach 1:
The heat exchanger circuits are integrated within the housing of the process valve manifold, creating a nested structure where one system is contained within another. This nesting approach reduces spatial requirements while maintaining all necessary thermal management functions
Solution Approach 2:
Multiple operating modes (heating, cooling, defrosting) are achieved within a single integrated unit by combining the valve manifold with heat exchanger circuits that can be selectively activated, eliminating the need for separate external modules for each function
3Productivity
If integrated thermal management is implemented in the process valve manifold, then system compactness and efficiency are improved, but manufacturing complexity increases
Solution Approach 1:
The integrated system is designed with modular components that can be manufactured separately and then assembled. The housing, valve manifold, and heat exchanger circuits are structured as distinct segments that can be produced using standard manufacturing processes before being combined into the final integrated unit
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
Enables highly integrated thermal management with optimized heat distribution and consumption, reducing energy and spatial requirements, and allowing for various operating modes without external components, enhancing overall system efficiency.
Implementation Method 1
The 3/2-way valve is switchable between different positions. The positions determine a flow cross-section by which the bypass outlet and the main outlet are in communication with the main duct
Implementation Method 2
at least one throttle is arranged in the main duct. The throttle can be used for adjusting a desired pressure gradient, so that, for example, a circulation is obtained in one of the secondary circuits
Implementation Method 3
a fluid communication existing between the main outlet and the inlet of the process valve manifold and running through a cooling duct of a prime mover
Data Source
AI summary
A process valve manifold comprises an inlet for a heat transfer medium, a main outlet for the heat transfer medium, a main duct extending between the inlet and the main outlet, ports for secondary circuits, a 3/2-way valve which is arranged in the main duct, and a bypass outlet. The 3/2-way valve is switchable between different positions. The positions determine a flow cross-section by which the bypass outlet and the main outlet are in communication with the main duct. The manifold further comprises control valves for determining a flow cross-section between the main duct and the ports for the secondary circuits.