Thermal Accumulator Assembly Integrating Expander for Waste Heat Recovery
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Solution Overview
Problem
Current waste heat recovery systems for vehicles are complex and costly, limiting their integration into automobiles due to the minimal amount of energy recovered and the need for separate, discrete components that increase complexity and cost.
Innovation Solution
A thermal accumulator assembly utilizing a two-phase coolant with a hermetically sealed housing and an expander generator, which integrates key components of the waste heat recovery system into a single assembly, reducing the need for external connections and protective covers, and allowing heat exchangers to be designed for working pressure rather than burst pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If waste heat recovery systems use separate discrete components with external connections, then the system can perform waste heat recovery, but the device complexity and cost increase
Solution Approach 1:
The patent integrates the heat exchanger, expander, and coolant circulation system into a single thermal accumulator assembly. The heat exchanger is positioned inside the accumulator housing with direct thermal coupling to the stored coolant, eliminating the need for external heat exchanger components and their associated piping. This merging of functions reduces device complexity while maintaining waste heat recovery capability.
Solution Approach 2:
The thermal accumulator assembly serves multiple functions simultaneously: it stores thermal energy in two-phase coolant, performs heat exchange with the vehicle cooling system, generates electricity through the expander, and regulates system pressure. This multi-functionality eliminates the need for separate discrete components for each function, reducing overall system complexity.
2Loss of energy
If waste heat recovery systems use separate discrete components, then the system can operate, but the manufacturing cost increases
Solution Approach 1:
By combining the heat exchanger, expander, and accumulator housing into a single integrated assembly, the patent reduces the number of separate parts that need to be manufactured, shipped, and assembled. This integration reduces manufacturing costs through economies of scale and reduced assembly complexity.
Solution Approach 2:
The heat exchanger is nested within the accumulator housing, and the expander is positioned within the same housing. This nested arrangement reduces the overall system volume and eliminates the need for external mounting brackets, fasteners, and protective covers, thereby reducing manufacturing costs.
3Reliability
If heat exchangers are designed for burst pressure, then safety is ensured, but the heat exchanger plate thickness and weight increase
Solution Approach 1:
The accumulator housing is designed to withstand burst pressure and serves as the protective containment structure. The heat exchanger plates only need to handle working pressure differential, as the housing provides the primary safety containment. This separation of safety function from heat exchange function allows thinner, lighter heat exchanger plates.
4Ease of manufacture
If separate discrete components are used with external tubes and hoses, then the system can be assembled, but the packaging space requirement increases
Solution Approach 1:
By integrating all components into a single assembly, the patent eliminates the volume occupied by external tubes, hoses, connectors, and mounting brackets. The compact integrated design reduces packaging space while maintaining assembly capability through standardized manufacturing processes.
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
This integration simplifies assembly, reduces costs, increases packaging space, and enhances efficiency by eliminating external tubes and hoses, allowing for thinner heat exchanger plates and reduced fluid charge, while generating power from waste heat to offset vehicle component consumption.
Implementation Method 1
The first chamber is configured as a reservoir for the two-phase coolant, and the expander is configured to receive a flow of vapor coolant from the first chamber to generate power via the motor generator
Implementation Method 2
a condensing heat exchanger disposed within the first chamber and configured to receive a second supply of coolant from the WHRS for thermal exchange with the first supply of coolant in the first chamber
Data Source
AI summary
A thermal accumulator assembly (TAA) for a vehicle waste heat recovery system (WHRS) utilizing a two-phase coolant includes a hermetically sealed housing having a separator plate dividing an interior of the housing into a higher pressure first chamber and a lower pressure second chamber, and an expander generator disposed between the first and second chambers and including an expander operably coupled to a motor generator. The first chamber is configured as a reservoir for the two-phase coolant, and the expander is configured to receive a flow of vapor coolant from the first chamber to generate power via the motor generator.