U-Flow Heat Exchange Manifold for Lower Pressure Drop
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Solution Overview
Problem
Heat exchange systems in electric vehicle batteries face challenges in maintaining optimal temperature, as existing heat exchange tubes suffer from high pressure losses and fluid leakage, especially when using a "U" flow configuration, which affects the efficiency and longevity of battery cells.
Innovation Solution
A manifold design for heat exchange tubes that allows fluidic communication between the forward and return flows with minimal pressure loss, featuring a collector made from deformed sheet metal pieces that connect the conduits with reduced resource usage and manufacturing operations, ensuring efficient heat transfer and leak prevention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional manifold designs are used to establish fluidic communication between forward and return flows, then heat exchange function is achieved, but pressure losses are high and fluid leakage occurs
Solution Approach 1:
The manifold is divided into a first part and a second part that are joined together, with the channel formed by expansion of these separate pieces. This segmentation allows for better flow management and reduced pressure losses while maintaining sealing integrity between the forward and return flow conduits.
Solution Approach 2:
The channel is formed by expansion in the transverse direction, creating a three-dimensional flow path that connects the forward and return conduits. This dimensional approach allows for optimized flow transitions that reduce pressure losses compared to conventional two-dimensional manifold designs.
2Loss of energy
If complex manifold designs are used to reduce pressure losses, then pressure drop is improved, but manufacturing complexity and resource usage increase
Solution Approach 1:
The manifold is constructed from a first part and a second part that can be manufactured separately and then joined together. This segmentation enables simplified manufacturing of each individual part while achieving the complex three-dimensional channel geometry needed for reduced pressure losses through expansion formation.
Solution Approach 2:
The channel is formed by expansion of the first and/or second parts, changing the physical state and geometry of the material during manufacturing. This expansion process creates the optimized three-dimensional flow path with reduced pressure losses using standard manufacturing techniques rather than complex assembly operations.
3Reliability
If traditional manifold configurations are used, then fluidic connection is established, but the structure requires excessive resources and manufacturing operations
Solution Approach 1:
The first part and second part of the manifold are joined together to form an integrated structure that provides both fluidic connection and structural support. This merging eliminates the need for separate components and reduces overall resource usage while maintaining reliable fluidic communication between forward and return flows.
Solution Approach 2:
The channel is created through expansion of the manifold parts rather than requiring separate molded or machined components. This parameter change in the manufacturing approach reduces material waste and resource consumption while ensuring reliable fluidic connection through the integrated expansion-formed structure.
Data Source
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AI summary
A first aspect of the invention is a manifold for heat exchange tube, the tube configured to carry out the cooling of an electrical or electronic element by making use of a "U" flow, that is, with a flow out and a flow back such that the fluid supply and the fluid outlet are located at one end of the tube. The manifold is configured to allow fluidic connection between the flow and return flow in the U-flow located at the end of the heat exchange tube. The manifold allows for a change of flow direction with improved pressure drop. The tube is additionally configured to establish a proper coupling to the manifold.