U-Flow Heat Exchange Tube With Manifold Isolation Against Bypass Flow
Solution Overview
Problem
Heat exchange systems for electric vehicle batteries face challenges in maintaining optimal temperature, as existing flat heat exchange tubes can suffer from bypass flows, reducing performance and efficiency, especially in 'U' flow configurations where accidental communication between flow and return conduits can occur, leading to hydraulic resistance issues and reduced heat transfer effectiveness.
Innovation Solution
A heat exchange tube with a 'U' flow configuration and a manifold design that prevents bypass flows by using recessed sections and separate connections for the flow and return conduits, ensuring a closed path and structural reinforcement through internal channels, and a manifold fabricated using sheet metal stamping and bending techniques to maintain contact with battery cells effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a flat heat exchange tube with 'U' flow configuration is used, then the tube can adapt to battery cell shapes and maximize contact region, but accidental communication between flow and return conduits can occur causing bypass flows that reduce heat transfer effectiveness
Solution Approach 1:
The flat heat exchange tube is divided into two separate conduits (flow conduit and return conduit) that are mechanically joined but fluidically isolated. The intermediate section connects the conduits structurally while the recessed perimeter areas ensure fluidic separation, preventing bypass flows while maintaining structural integrity for effective battery cell contact.
Solution Approach 2:
The intermediate section acts as an intermediary element that mechanically joins the flow conduit and return conduit while maintaining their fluidic independence. The recessed perimeter areas in the intermediate section create a barrier that prevents accidental communication between the conduits, ensuring reliable heat transfer.
2Ease of operation
If the flow supply and flow return are located on the same side of the tube, then a manifold is needed to communicate both channels, but this increases device complexity and risk of bypass flows
Solution Approach 1:
The manifold integrates multiple functions into a single structure: it provides fluidic communication between the flow and return conduits, establishes separate connection points for supply and return lines, and prevents bypass flows through its chamber design. The first and second chambers are fluidically isolated yet structurally integrated, simplifying the overall system.
Solution Approach 2:
The manifold extracts and separates the fluidic communication paths into distinct chambers (first chamber for flow conduit, second chamber for return conduit). This extraction of fluidic functions into separate chambers prevents accidental communication and bypass flows while maintaining ease of connection.
3Ease of manufacture
If the intermediate section connects both conduits at the same level, then fabrication is simplified, but bypass flows can occur between conduits reducing system reliability
Solution Approach 1:
The intermediate section has different properties in different regions: the central area provides structural connection and fluidic isolation between conduits, while the recessed perimeter areas specifically prevent bypass flows. This local differentiation of quality ensures both manufacturing feasibility and reliable fluidic isolation.
4Ease of manufacture
If the tube uses a straight configuration, then manufacturing is easier, but it cannot adapt to cylindrical battery cell surfaces reducing heat exchange efficiency
Solution Approach 1:
The flat tube is configured with a sinuous or wavy trajectory instead of a straight line, allowing it to adapt to the cylindrical surfaces of battery cells. This curvature increases the contact region area and improves heat exchange efficiency while maintaining the flat tube's manufacturing advantages through standard sheet metal forming techniques.
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 effectively prevents bypass flows, enhances heat transfer efficiency, and maintains structural integrity, ensuring reliable performance across varying temperature conditions for both charging and storage, thereby extending battery life and maintaining performance.
Implementation Method 1
a cooling liquid through its interior for transporting the heat exchanged between the tube and the element to be heated or cooled
Implementation Method 2
the cells generate heat that must be dissipated so that their temperature does not rise excessively
Data Source
AI summary
A first aspect of the invention is a heat exchange tube configured to carry out the cooling of an electrical or electronic element by making use of a “U” flow, that is, with an outflow and a return flow such that the supply and outlet of the fluid are located at one end of the tube. The tube is additionally configured to establish a suitable coupling to a manifold so that the junction ensures that there is no bypass flow between the flow channel(s) and the return flow channel(s). A second aspect of the invention is a manifold configured for coupling with the tube of the first aspect of the invention. A third aspect of the invention is a heat exchange module which at least combines a tube according to the first aspect of the invention and a collector according to the second aspect of the invention.