U-Flow Heat Exchange Tube With Bypass-Free Manifold Coupling
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Solution Overview
Problem
Heat exchange systems for battery cells face challenges in maintaining optimal operating temperatures, as existing flat heat exchange tubes can experience bypass flows, reducing performance and efficiency, especially in electric vehicles where temperature management is critical for both charging and storage conditions.
Innovation Solution
A heat exchange tube with a 'U' flow configuration and a manifold design that prevents bypass flows by ensuring differentiated and secure connections between the supply and return channels, using a flat tube with internal channels for structural reinforcement and a manifold constructed from stamped sheet metal for efficient assembly and leak prevention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a flat heat exchange tube with supply and return channels is used, then the tube can adapt to the shape of battery cells and maximize contact region, but bypass flows occur between the flow channels reducing heat transfer efficiency
Solution Approach 1:
The flat heat exchange tube is segmented into multiple independent flow channels separated by partitions. These partitions divide the tube interior into distinct supply channels and return channels, preventing bypass flows while maintaining the flat configuration that adapts to battery cell shapes. The segmentation ensures that coolant flows through the intended path for effective heat transfer.
Solution Approach 2:
Different regions of the flat heat exchange tube have different functions: some regions have supply channels while others have return channels, with partition walls separating them. The tube surface contact regions are optimized for heat transfer, while the internal channel structure is optimized to prevent bypass flows. This local differentiation allows the tube to maintain both adaptability to cell shapes and reliable heat transfer efficiency.
2Ease of manufacture
If the supply and return channels are located at the same end of the tube, then the manifold connection is simplified, but it becomes difficult to prevent bypass flows between channels
Solution Approach 1:
The tube is segmented with internal partition walls that create distinct supply and return channels extending from one end to the other. Even though supply and return manifolds connect at the same end, the partitions ensure that coolant in the supply channel cannot bypass into the return channel, maintaining flow separation and heat transfer efficiency while allowing simplified manifold connection geometry.
Solution Approach 2:
Partition walls act as intermediaries between the supply channel and return channel. These partitions physically separate the two flow paths, preventing direct communication or bypass flows between supply and return channels at the manifold connection end. The partitions serve as mediators that maintain flow directionality while allowing the simplified same-end connection configuration.
3Ease of operation
If traditional manufacturing methods are used for the manifold, then assembly is straightforward, but the number of fabrication steps increases and cross flows between feed and return channels may occur
Solution Approach 1:
The manifold is designed as a single integrated stamping piece that incorporates both supply and return channel connections in one component. This merging of functions into a single manufactured part reduces the number of fabrication steps and assembly operations compared to traditional multi-component manifold designs, while the internal geometry of the stamping prevents cross flows between feed and return channels.
Solution Approach 2:
The manifold geometry is optimized through stamping process parameters to create internal flow path restrictions that prevent cross flows. The stamping technique allows for precise control of wall thickness, channel dimensions, and connection geometries, enabling the manifold to maintain simple assembly while preventing harmful bypass flows through carefully controlled physical parameters of the formed structure.
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, enhancing heat transfer efficiency and maintaining optimal battery cell temperatures, thereby extending battery life and ensuring reliable performance in varying conditions.
Implementation Method 1
heat exchange tube configured to carry out the cooling of an electrical or electronic element by making use of a 'U' flow... allowing the passage of a cooling liquid through its interior for transporting the heat exchanged with the tube and the element to be heated or cooled
Data Source
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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.