Welded Plate Heat Exchanger for Low-Profile Battery Cooling
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Solution Overview
Problem
Existing heat exchangers for battery electric vehicles (BEVs) are bulky and complex, occupying excessive vertical space due to tubular cooling pipes and multiple components, complicating assembly and reducing arrangement flexibility.
Innovation Solution
A heat exchanger design featuring overlapping metal plates to form flow paths, eliminating the need for connectors and pipes, with supply and discharge modules integrated through welding, allowing for a compact and simplified structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If tubular cooling pipes and connectors are used to supply and discharge fluid, then heat exchange function is achieved, but the dimension in up-down direction increases and assembly process becomes complex
Solution Approach 1:
The patent merges the cooling pipe and connector into a single integrated component. The pipe end is directly formed with a connector structure, eliminating the need for separate connector parts and simplifying the assembly process while reducing the overall up-down dimension of the heat exchanger.
Solution Approach 2:
The pipe structure is designed to perform multiple functions: it serves as both the cooling fluid passage and the connection interface with batteries. The pipe end is formed to directly connect with battery connectors, making the pipe a multi-functional component that reduces both part count and assembly complexity.
2Volume of moving object
If tubular cooling pipes with larger outer diameter are used, then fluid flow capability is sufficient, but arrangement space increases
Solution Approach 1:
The patent transitions from a traditional horizontal pipe layout to a vertical arrangement where multiple pipes are stacked in the up-down direction. This dimensional reorganization allows sufficient fluid flow capability through multiple parallel channels while minimizing the horizontal arrangement space, fitting better in constrained vehicle battery compartments.
3Adaptability or versatility
If multiple separate components (joint, three-way valve, rubber pipe) are used, then fluid distribution flexibility is achieved, but number of components increases
Solution Approach 1:
The patent combines multiple separate components (joint, three-way valve, rubber pipe) into an integrated molded structure. The connector is formed as a single piece with integrated flow distribution channels, eliminating the need for multiple separate parts while maintaining fluid distribution flexibility through internally designed passage configurations.
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 design reduces vertical dimensions, simplifies assembly, and enhances space efficiency while maintaining heat exchange performance, making it suitable for small arrangement spaces.
Implementation Method 1
an upper metal plate having an arc-shaped cross section that protrudes upward and a lower metal plate processed to have a circular cross section that protrudes downward can be joined by a technique such as welding to form a channel
Implementation Method 2
a heat exchange module (1) having a heat exchange flow path (Da) formed inside by overlapping and joining a plurality of metal plates
Data Source
Figure 1
Figure 2
Figure 3~6
AI summary
A heat exchanger (A), through which a fluid to be heat-exchanged with a battery mounted on a vehicle flows, includes: a plurality of heat exchange modules (1) each having a heat exchange flow path formed inside by overlapping and joining a plurality of metal plates, a supply port through which the fluid is sent to the heat exchange flow path, and a discharge port through which the fluid is sent out from the heat exchange flow path; a supply flow path module (2) joined to each of the plurality of heat exchange modules and configured to supply the fluid from the supply port of each of the plurality of heat exchange modules; and a discharge flow path module (3) joined to each of the plurality of heat exchange modules and configured to discharge the fluid from the discharge port of each of the plurality of heat exchange modules. In at least one of the supply flow path module and the discharge flow path module, a flow path through which the fluid flows is formed inside by overlapping and joining a plurality of metal plates.