Vehicle Heat Exchanger Modular Core Segmentation
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Solution Overview
Problem
Conventional shell tube heat exchangers for vehicles face challenges in heat transfer efficiency, durability, and maintenance due to high pressure and temperature conditions, limited design freedom, and the accumulation of particulate matter, which reduces performance and increases manufacturing costs.
Innovation Solution
A heat exchanger design featuring a housing with a header and a heat exchange core composed of thin plate half-shells with grooves, allowing for improved pressure resistance and heat transfer efficiency, along with a modular structure for easy assembly and cleaning, and elastic support for stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If shell tube type heat exchanger is used to ensure pressure resistance and component reliability, then durability is improved, but device complexity and weight increase
Solution Approach 1:
The heat exchanger is divided into a header section and a core section that can be separately manufactured and then assembled together. The core elements are spaced apart from each other and coupled to the header, allowing for modular construction that reduces overall complexity while maintaining pressure resistance through the header design.
2Reliability
If shell tube type heat exchanger is used for pressure resistance, then durability is improved, but weight increases
Solution Approach 1:
The heat exchanger is divided into a header section and a core section that can be separately manufactured and then assembled together. The core elements are spaced apart from each other and coupled to the header, allowing for modular construction that reduces overall complexity while maintaining pressure resistance through the header design.
3Reliability
If conventional shell tube heat exchanger is used, then pressure resistance is achieved, but manufacturing cost increases due to separate insulation requirements
Solution Approach 1:
The header serves a dual function as both a pressure-resistant structural component and an integrated insulation barrier. By combining the insulation function into the header structure itself, separate insulation components and assembly steps are eliminated, reducing manufacturing complexity and cost while maintaining pressure resistance.
4Use of energy by moving object
If heat exchanger tube is used for thermal fluid passage, then heat transfer is achieved, but particulate matter accumulates and blocks the tube interior
Solution Approach 1:
The heat exchange core is divided into multiple spaced-apart core elements rather than a single continuous tube. This segmentation creates multiple flow paths and prevents complete blockage by particulate matter, while maintaining effective heat transfer surface area through the combined core elements.
Solution Approach 2:
The harmful accumulation of particulate matter is addressed by making the core elements removable from the header. This allows for easy extraction and cleaning of the core elements to remove accumulated particulate matter, restoring heat transfer performance without replacing the entire heat exchanger.
5Use of energy by moving object
If heat exchanger tube is installed in shell interior, then heat exchange function is achieved, but contaminants cannot be easily washed
Solution Approach 1:
The heat exchange core is divided into multiple spaced-apart core elements rather than a single continuous tube. This segmentation creates multiple flow paths and prevents complete blockage by particulate matter, while maintaining effective heat transfer surface area through the combined core elements.
Solution Approach 2:
The harmful accumulation of particulate matter is addressed by making the core elements removable from the header. This allows for easy extraction and cleaning of the core elements to remove accumulated particulate matter, restoring heat transfer performance without replacing the entire heat exchanger.
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
Enhances heat transfer performance, durability, and ease of maintenance by maximizing fluid contact area, ensuring reliable operation under high-pressure conditions and allowing for effective washing of particulate matter, while reducing manufacturing costs.
Implementation Method 1
a heat exchanger that may improve a heat transfer performance between two or more fluids
Implementation Method 2
heat transfers between two or more fluids
Implementation Method 3
the first fluid is introduced into a first fluid inlet manifold... the second fluid is introduced into a second fluid inlet manifold
Data Source
AI summary
A heat exchanger for a vehicle includes: a housing having an interior space; a header installed at one end of the housing and having a first fluid inlet manifold; a second fluid inlet manifold; and a second fluid outlet manifold; and a heat exchange core installed in the interior of the housing and having a plurality of core elements spaced apart from each other. The plurality of core elements are coupled to the header, and a plurality of first fluid passage, through which the first fluid passes, is respectively formed between the adjacent core elements. Each of the core elements has a second fluid passage, through which the second fluid flows, an inlet of the second fluid passage communicates with the second fluid inlet manifold, and an outlet of the second fluid passage communicates with the second fluid outlet manifold.