Stacked Disc Heat Exchanger Module to Reduce Installation Complexity
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Solution Overview
Problem
Existing heating/cooling modules for vehicles are complex, prone to errors, and require extensive installation effort due to numerous connections and separate components, lacking a compact design and efficient integration of heat exchangers.
Innovation Solution
A stacked disc design with integrated condenser, evaporator, and fluid distribution regions, featuring flow channels between disc elements, thermostatic expansion valves, and optional internal heat exchangers, which reduces connections and allows for a compact, efficient layout with flexible fluid routing and maintenance-friendly design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate heat exchanger components are used to achieve heating and cooling functions, then the required heat exchange functions are provided, but the device complexity and installation effort increase significantly
Solution Approach 1:
The patent combines condenser, evaporator, and fluid distribution regions into a single integrated heat exchanger module with a stacked disc design. Multiple disc elements create flow channels that accommodate refrigerant and coolant circuits, merging functions that would traditionally require separate components into one unified structure.
Solution Approach 2:
The integrated heat exchanger module performs multiple functions simultaneously: condensation, evaporation, fluid distribution, and heat exchange. The stacked disc structure with interconnected flow channels enables the system to handle both refrigerant flow and coolant flow through a single component assembly, providing universal thermal management capability.
2Adaptability or versatility
If multiple separate heat exchanger components are connected together, then the required heat exchange functions are provided, but the space requirement and assembly effort increase
Solution Approach 1:
The stacked disc design nests multiple functional regions within each other. The condenser region, evaporator region, and fluid distribution regions are arranged in a compact stacked configuration where disc elements create flow channels between them. This nesting approach allows multiple heat exchange functions to occupy overlapping or adjacent spaces that would be separate in traditional designs.
Solution Approach 2:
The patent transitions from a planar arrangement of separate heat exchanger components to a three-dimensional stacked disc structure. By utilizing the vertical dimension and creating flow channels between stacked disc elements, the design achieves compact integration of multiple functions in a space-efficient configuration.
3Adaptability or versatility
If multiple connecting lines are provided to connect separate components, then the required heat exchange functions are provided, but the assembly effort and error susceptibility increase
Solution Approach 1:
The patent integrates multiple heat exchange functions into a single manufactured unit with pre-formed flow channels between disc elements. This merging eliminates the need for multiple external connecting lines and joints, allowing the entire assembly to be produced as one integrated component or pre-assembled module, significantly reducing assembly complexity and potential error sources.
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 provides a compact, efficient, and easy-to-manufacture heating/cooling module with reduced installation complexity, improved heat transfer efficiency, and enhanced reliability by integrating multiple heat exchanger functions within a single structural unit.
Implementation Method 1
a thermostatic expansion valve through which refrigerant can flow
Implementation Method 2
a thermostatic expansion valve through which refrigerant can flow
Implementation Method 3
a condenser region with a first flow section, through which a refrigerant can flow, and has a second flow section, through which a coolant can flow
Implementation Method 4
a condenser region with a first flow section, through which a refrigerant can flow
Implementation Method 5
an evaporator region with a third flow section, through which a refrigerant can flow, and has a fourth flow section, through which a coolant can flow
Implementation Method 6
an evaporator region with a third flow section, through which a refrigerant can flow
Data Source
AI summary
A heating/cooling module having a condenser region, an evaporator region, and at least one fluid distribution region. The condenser region has a first flow section which can be flowed through by a refrigerant and a second flow section which can be flowed through by a coolant. The evaporator region has a third flow section which can be flowed through by a refrigerant and a fourth flow section which can be flowed through by a coolant. The flow sections are formed by a plurality of flow ducts which are configured between the individual disc elements which form the heating/cooling module. A first fluid inlet and a first fluid outlet are provided, via which the condenser region can be flowed through with a coolant. A second inlet and a second outlet are provided, via which the evaporator region can be flowed through with a coolant.