U.S. patent application number 17/428662 was filed with the patent office on 2022-04-21 for universal heat exchanger.
The applicant listed for this patent is PRANAV VIKAS INDIA PVT LIMITED. Invention is credited to Sanjay Chawla, Dakshinamurthy Govindaraj, Poonam Hyanki, Vijayaraghavan. S., K Srinivas, Hemanshu Yadav, Yuji YAMAMOTO.
Application Number | 20220120506 17/428662 |
Document ID | / |
Family ID | |
Filed Date | 2022-04-21 |
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United States Patent
Application |
20220120506 |
Kind Code |
A1 |
YAMAMOTO; Yuji ; et
al. |
April 21, 2022 |
UNIVERSAL HEAT EXCHANGER
Abstract
A heat exchanger (100) having a plurality of plates (101)
manufactured preferably but not limiting to the stamping process,
the plates has been configured to accommodate the internal fins
(106). The plates (101) also define plurality of the passages (102)
for flowing at least two fluids. A plurality of conduits (103)
fluidly coupled to a first end and second of the end of the plates
(101) which allows the flow of the fluids. At least one inlet (104)
coupled to a first end, and at least one outlet (105) coupled to
the second end of the plurality of plates (101) configured to allow
the flow of the fluids wherein each fluid flow in a different
direction from the other, a plurality of inner fins (106) disposed
on a surface of each of the plurality of plates (101) for
increasing the surface to volume ratio of the first and second
fluid to achieve pre-defined thermal performance.
Inventors: |
YAMAMOTO; Yuji; (Faridabad,
Haryana, IN) ; Chawla; Sanjay; (Faridabad, Haryana,
IN) ; Yadav; Hemanshu; (Faridabad, Haryana, IN)
; Hyanki; Poonam; (Faridabad, Haryana, IN) ; S.;
Vijayaraghavan.; (Faridabad, Haryana, IN) ;
Govindaraj; Dakshinamurthy; (Faridabad, Haryana, IN)
; Srinivas; K; (Faridabad, Haryana, IN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
PRANAV VIKAS INDIA PVT LIMITED |
Faridabad, Haryana |
|
IN |
|
|
Appl. No.: |
17/428662 |
Filed: |
March 19, 2019 |
PCT Filed: |
March 19, 2019 |
PCT NO: |
PCT/IN2019/050222 |
371 Date: |
August 5, 2021 |
International
Class: |
F28D 9/00 20060101
F28D009/00; F28F 3/02 20060101 F28F003/02; F28F 3/08 20060101
F28F003/08 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 5, 2019 |
IN |
201911004537 |
Claims
1) A heat exchanger (100) comprising: a plurality of plates (101)
configured to define a plurality of flow passages for flowing at
least two fluids; a plurality of conduits fluidly coupled to a
first end and a second end of the plates to allow the flow of the
fluids; at least one inlet coupled to the first end, and at least
one outlet coupled to the second end of the plurality of plates
configured to allow the flow of the fluids wherein each fluid flow
in a different direction from the other; a plurality of inner fins
disposed on a surface of each of the plurality of plates for
increasing the surface to volume ratio of the first and second
fluid to achieve pre-defined thermal performance.
2) The heat exchanger as claimed in claim 1, wherein the fluids
flow in the opposite direction from the other.
3) The heat exchanger as claimed in claim 1, wherein the fluids are
either a refrigerant or a coolant.
4) The heat exchanger as claimed in claim 1, wherein the plurality
of the inner fins are non-louvered straight wavy fins configured to
produce laminar flow.
5) The heat exchanger as claimed in claim 1, wherein the inner fins
are disposed on the plain plate area.
6) The heat exchanger as claimed in claim 1, wherein the plurality
of plates are dumbbell-shaped stamped plates capable to interlock
while stacking on each other.
7) The heat exchanger as claimed in claim 1, wherein the plurality
of plates are having a pre-defined specific thickness.
8) The heat exchanger as claimed in claim 1, wherein a stiffener is
placed in one of the plates of the heat exchanger for high-pressure
application.
9) The heat exchanger as claimed in claim 1, wherein the plate has
a plurality of embossing and a plurality of fin stoppers.
10) The heat exchanger as claimed in claim 1, wherein the heat
exchanger work as three different heat exchangers such as Chiller
or W-Condenser or Plate IHX as per the requirement by changing the
inlet/outlet connections with a common core.
Description
FIELD OF THE INVENTION
[0001] The present invention generally relates to heat exchangers.
In particular, the invention relates to heat exchangers for
automobiles. More particularly, the invention relates to a heat
exchanger that can be used for low-pressure applications as well as
for high-pressure applications.
BACKGROUND OF THE INVENTION
[0002] Batteries play an important role in powering all types of
electric vehicles. Nowadays, there is a growing demand for
lithium-ion batteries in various applications, particularly for
electric vehicles, which require a more reliable battery thermal
management system for controlling the battery temperature. Due to
their high energy density, low self-discharge rate, and long cycle
life, lithium-ion batteries are the main source of power in
electric vehicles. The thermal safety of lithium-ion batteries
during their application has become the main issue. In the past few
years, researchers and automotive manufacturers have been focusing
on the cooling of Li-ion batteries as this is a major obstacle in
the development of electric vehicles.
[0003] In addition, one of the limitations of the battery is with
regard to thermal control. When the battery is operated at a low
temperature, the power output will be reduced due to the
suppression of the electrochemical reactions, while a high
temperature will accelerate corrosion, thus leading to reduced
battery life. Other than that, the temperature range and uniformity
in a pack are significant factors for obtaining optimum performance
from an EV battery pack. An excessive rise in the local temperature
in Li-ion batteries will cause a reduction in the life cycle and
may lead to the occurrence of thermal runaway in an individual cell
or in the entire battery pack. Thermal runaway is a failure mode in
the battery and it may cause a fire and an explosion if the thermal
management system in the battery is ineffective. Therefore, it is
necessary to introduce a cooling method for the Li-ion battery to
ensure that it has an effective thermal management system. There
are several types of cooling methods for Li-ion batteries such as
air cooling, liquid cooling and the use of phase change materials.
Air cooling is widely used as a cooling method in order to ensure
that the Li-ion battery is safe, reliable and has a long operating
life. In addition, temperature uniformity in the battery module can
be improved by using the air cooling method. This method has its
limitations, and it is suitable for a low energy density Li-ion
battery. If the battery has a high energy density, then a liquid
cooling system provides the most effective thermal management.
[0004] A Chiller is used in electric vehicles for cooling the
battery. The Chiller is a heat exchanger which is used to remove
heat from the battery and passing it to the refrigerant to sink the
heat to the atmosphere. A water-cooled condenser or W-condenser can
be used in electric vehicles (EV's) for cabin heating. It also
increases sub-cooling of refrigerant in the refrigerant circuit. An
IHX is a liquid to vapor heat exchanger. IHX transfers heat from
the liquid refrigerant (After condenser) to vapor refrigerant
(After evaporator). IHX sub-cools refrigerant from condenser
further below condensation temperature. It also prevents liquid
refrigerant to enter into the compressor. Also, IHX is being used
today is to get away with using less refrigerant. Plate IHX
(Internal Heat Exchanger) will improve the efficiency and packaging
space as compared to existing tubular type IHX. Plate IHX can also
be used in ICE automobiles.
[0005] However, these heat exchangers face various problems such as
limited space available in the vehicle engine compartment, high
thermal performance requirements, less development time for the
non-standard designs, less tooling cost demand due to competition,
less part weight as a part of light weighting programs for better
vehicle performance and fuel efficiency, less part cost to be
competitive in the market, development of large number of child
parts, heavy components to meet the structural/Integrity
requirements.
Objective of the Invention
[0006] The object of the invention is to provide on a universal
heat exchanger design for three different applications Chiller
(Low-Pressure Application), w-condenser (High-Pressure Application)
and plate IHX (High-Pressure Application).
[0007] Another object of the invention is to provide an inner fin
in plate heat exchanger applications such as a chiller,
W-condenser, and Plate IHX heat exchangers.
[0008] Another object of the invention is to provide internal fins
to increase the surface to volume ratio for both coolant and
refrigerant for high thermal performance.
[0009] Another object of the invention is to provide the shape of
the plates to accommodate inner fins for high-pressure
applications.
[0010] Another object of the invention is to provide a heat
exchange which works with counterflow between coolant and
refrigerant for high thermal performance.
[0011] Another object of the invention is to provide a light and
compact heat exchanger for better vehicle performance and fuel
efficiency.
[0012] Another object of the invention is to provide stamped plates
with a new design to increase the bulge and burst pressure of the
heat exchangers.
[0013] Another object of the invention is to provide a heat
exchanger with no internal leakage or intermixing of two fluids in
the heat exchanger.
SUMMARY OF THE INVENTION
[0014] The present invention relates to a heat exchanger comprising
a plurality of plates configured to define a plurality of flow
passages for flowing at least two fluids, a plurality of conduits
fluidly coupled to a first end and a second end of the plates to
allow the flow of the fluids, at least one inlet coupled to the
first end, and at least one outlet coupled to the second end of the
plurality of plates configured to allow the flow of the fluids
wherein each fluid flow in a different direction from the other,
preferably the fluids flow in the opposite direction from the
other, a plurality of inner fins disposed on a surface of each of
the plurality of plates for increasing the surface to volume ratio
of the first and second fluid to achieve pre-defined thermal
performance.
[0015] In an embodiment, the fluids are either a refrigerant or a
coolant.
[0016] In an embodiment, the plurality of the inner fins are
non-louvered straight wavy fins configured to produce laminar flow.
Preferably, the inner fins are disposed on the plain plate
area.
[0017] In an embodiment, the plurality of plates are
dumbbell-shaped stamped plates capable to interlock while stacking
on each other. Preferably, the plurality of plates are having a
pre-defined specific thickness.
[0018] In an embodiment, a stiffener is placed in one of the plates
of the heat exchanger for the high-pressure application.
[0019] In an embodiment, the plate has a plurality of embossing and
a plurality of fin stoppers.
[0020] In an embodiment, the heat exchanger works as three
different heat exchangers such as Chiller or W-Condenser or Plate
IHX as per the requirement by changing the inlet/outlet connections
with a common core.
BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS
[0021] The foregoing and further objects, features, and advantages
of the present subject matter will become apparent from the
following description of exemplary embodiments with reference to
the accompanying drawings, wherein like numerals are used to
represent like elements.
[0022] It is to be noted, however, that the appended drawings
illustrate only typical embodiments of the present subject matter,
and are, therefore, not to be considered for limiting of its scope,
for the subject matter may admit to other equally effective
embodiments.
[0023] FIG. 1. illustrates the exploded view of the present
invention with both fluids flow direction in accordance with one
embodiment of the present subject matter;
[0024] FIG. 2(a). illustrates the perspective view of the present
invention in accordance with one embodiment of the present subject
matter;
[0025] FIG. 2(b). illustrates the exploded view of the present
invention Chiller in accordance with one embodiment of the present
subject matter;
[0026] FIG. 2(c). illustrates the exploded view of the present
invention w-condenser in accordance with one embodiment of the
present subject matter;
[0027] FIG. 2(d). illustrates the exploded view of the present
invention plate IHX in accordance with one embodiment of the
present subject matter;
[0028] FIG. 3. illustrates the inner fins of the present invention
in accordance with one embodiment of the present subject
matter;
[0029] FIG. 4(a). illustrates the perspective view of the inner
fins between the plates in accordance with one embodiment of the
present subject matter;
[0030] FIG. 4(b). illustrates the front view of the interlocked
plates in accordance with one embodiment of the present subject
matter;
[0031] FIG. 5(a). illustrates the perspective view of the plate in
accordance with one embodiment of the present subject matter;
[0032] FIG. 5(b). illustrates the perspective view of the plate in
accordance with one embodiment of the present subject matter;
[0033] FIG. 5(c). illustrates the perspective view of the plate in
accordance with one embodiment of the present subject matter;
[0034] FIG. 5(d). illustrates the perspective view of the plate in
accordance with one embodiment of the present subject matter;
[0035] FIG. 5(e). illustrates the perspective view of the plate in
accordance with one embodiment of the present subject matter;
[0036] FIG. 6. illustrates the perspective view of the plate along
with the internal fins in accordance with one embodiment of the
present subject matter;
[0037] FIG. 7. illustrates the cut view of the stacked plates along
with the internal fins in accordance with one embodiment of the
present subject matter;
[0038] FIG. 8(a). illustrates the plate along with embossing and
stopper in accordance with one embodiment of the present subject
matter;
[0039] FIG. 8(b). illustrates the Section X-X showing plate
embossing with fin stopper in accordance with one embodiment of the
present subject matter;
[0040] FIG. 9. illustrates the plate using a stiffener for the
high-pressure application.
DETAILED DESCRIPTION
[0041] The following presents a detailed description of various
embodiments of the present subject matter with reference to the
accompanying drawings.
[0042] The embodiments of the present subject matter are described
in detail with reference to the accompanying drawings. However, the
present subject matter is not limited to these embodiments which
are only provided to explain more clearly the present subject
matter to a person skilled in the art of the present disclosure. In
the accompanying drawings, like reference numerals are used to
indicate like components.
[0043] The specification may refer to "an", "one", "different" or
"some" embodiment(s) in several locations. This does not
necessarily imply that each such reference is to the same
embodiment(s), or that the feature only applies to a single
embodiment. Single features of different embodiments may also be
combined to provide other embodiments.
[0044] As used herein, the singular forms "a", "an" and "the" are
intended to include the plural forms as well, unless expressly
stated otherwise. It will be further understood that the terms
"includes", "comprises", "including" and/or "comprising" when used
in this specification, specify the presence of stated features,
integers, steps, operations, elements, and/or components, but do
not preclude the presence or addition of one or more other
features, integers, steps, operations, elements, components, and/or
groups thereof. It will be understood that when an element is
referred to as being "attached" or "connected" or "coupled" or
"mounted" to another element, it can be directly attached or
connected or coupled to the other element or intervening elements
may be present. As used herein, the term "and/or" includes any and
all combinations and arrangements of one or more of the associated
listed items.
[0045] The figures depict a simplified structure only showing some
elements and functional entities, all being logical units whose
implementation may differ from what is shown.
[0046] FIG. 1 shows the exploded view of the present invention,
wherein it shows a heat exchanger (100) having a plurality of
plates (101) manufactured preferably but not limiting to the
stamping process, the plates have been configured to accommodate
the internal fins (106). The plates (101) also define a plurality
of the passages (102) for following at least two fluids. A
plurality of conduits (103) fluidly coupled to a first end and
second of the end of the plates (101) which allows the flow of the
fluids. At least one inlet (104) coupled to a first end, and at
least one outlet (105) coupled to the second end of the plurality
of plates (101) configured to allow the flow of the fluids wherein
each fluid flow in a different direction from the other, a
plurality of inner fins (106) disposed on a surface of each of the
plurality of plates (101) for increasing the surface to volume
ratio of the first and second fluid to achieve pre-defined thermal
performance. The fluids flow in the opposite direction creates a
counter flow. For counter flow between two fluids, inlet-outlet
ports are positioned diagonally opposite in each plate. Such that
both fluids flow in reverse direction on both sides of a plate
[0047] This particular configuration of the heat exchanger (100) is
focused on the development of three heat exchangers by using Plate
and Fin (PAF) concept with the counterflow for BCS, EVTMS Circuits
and ICE Automobiles. Changing requirements and constraints demands
significant flexibility in these heat exchanger (100) designs in
terms of thermal performance, refrigerant distribution uniformity,
non-standard aspect ratio (width/height of HEX), varying
refrigerant flow structure (multipass), development time and
cost.
[0048] FIG. 2 (a) shows the perspective view of the present
invention, this particular figure shows a chiller assembly of the
heat exchanger (100). The plates (101) are stacked together which
make the heat exchanger (100) very compact. The plates (101) may be
varied by the user depending on the application/thermal performance
requirement of the heat exchanger (100). The compact nature of the
heat exchanger (100) tends to be installed in any small to medium
size vehicles.
[0049] FIGS. 2(b), 2(c) and 2(d) illustrate a various configuration
which provides a multifunctional heat exchanger (HEX)(100) which
can be used for different pressure applications. A single design
concept is used for three different heat exchanger applications by
simply changing the inlet/outlet connections with a common core.
That means fewer inventories, lowest wastages, high quality, less
tooling cost, less development time and cost, and lower design,
material, and process related issues. Counterflow between two
fluids for maximum heat transfer.
TABLE-US-00001 Heat Exchanger Flow medium-1 Flow medium- 2 Chiller
Low pressure and low- Low pressure and high- temperature
refrigerant temperature coolant W-Condenser High pressure and high-
Low pressure and low- temperature refrigerant temperature coolant
P-IHX Low pressure and low- High pressure and high- temperature
refrigerant temperature refrigerant
[0050] FIG. 3. shows the inner fins (106) which are accommodated
between the plates (101). The internal fins (106) are designed to
accommodate the fins (106) between the plates (101) which enhances
high-pressure withstanding capability. The plurality of the inner
fins (106) are non-louvered straight wavy fins (106) configured to
produce laminar flow. Preferably, the inner fins (106) are disposed
on the plain plate area. They are preferably formed through a
stamping process.
[0051] FIGS. 4(a) and 4(b) shows the perspective and front view of
the inner fins (106) between the plates (101). The plates (101) are
configured to accommodate the internal fins (106), the plates (101)
are so formed that to allow the passage of the fluids through them.
The plates (101) are also interlocked which avoid leakage of the
fluids and intermixing of the two fluids.
[0052] FIG. 5(a), 5(b), 5(c), 5(d) and 5(e) shows the perspective
view of the stamped plate designs in accordance with one embodiment
of the present invention. These five different types of plates are
used in the development of all three heat exchangers. Preferably
but not limiting between 0.3 mm to 1 mm plate thickness is used in
the development of chiller, W-condenser and Plate IHX to make it a
light and compact heat exchanger (100) as a future heat exchanger
(100) technology for better vehicle performance and fuel
efficiency. The different thermal performance requirements can be
easily achieved by simply changing the number of plates (101) and
fin stacks or by changing a number of passes. The plates (101) are
so configured to accommodate the inner fins (106). The plates (101)
are preferably but not limited to have a dumbbell-shaped stamped
plates (101) which are capable to interlock while stacking on each
other.
[0053] FIG. 6 shows the plate along with the internal fins (106).
The inner fins (106) are usually disposed on the plain portion of
the plate. The fins (106) are so disposed that they are entirely
within the space provided over the plate. The interlocking of the
plates (101) does not deform the original shape of the internal
fins (106). The plates (101) have the passages and the inlet and
outlet ports which allow fluids to flow through them. The ports are
of the nature that it can close through a stopper on basis of their
applications.
[0054] FIG. 7 shows the cut view of the stacked plates (101) along
with the internal fins (106) in accordance with one embodiment of
the present subject matter. The plates (101) are so configured to
interlock, the dumbbell shape of the plates (101) helps the plates
(101) to be stacked and provide interlocking. Interlocking dumbbell
shape stamped plates (101) are used to increase the bulge and burst
pressure of the heat exchangers. It is achieved by optimizing the
unsupported area between internal fins (106) and I/O holes for a
plate.
[0055] FIG. 8(a) the plate along with embossing (107) and fin
stopper (109) in accordance with one embodiment of the present
subject matter. Embossing (107) is used to increase the bulge and
burst pressure of the heat exchanger. Fin stopper (109) is used to
stop the fin movement along the core length.
[0056] FIG. 8(b) shows a section view of the plates in the heat
exchanger assembly. FIG. 8(b) clearly shows how embossings are
brazed to the adjacent plates to increase the bulge and burst
pressure of the heat exchanger by reducing the unsupported area of
the plates for pressure load.
[0057] FIG. 9 shows the plate with a stiffener (108) for the
high-pressure application. Stiffener and increased thickness are
necessary for withstanding high-pressure loads in the localized
area. For high-pressure application in W-condenser and Plate IHX, a
stiffener is placed in one of the plates (101), preferably but not
limited to second last plate of the heat exchanger (100) to meet
the high burst pressure requirements of these two heat
exchangers
[0058] Although the invention has been described with reference to
specific embodiments, this description is not meant to be construed
in a limiting sense. Various modifications of the disclosed
embodiments, as well as alternate embodiments of the invention,
will become apparent to persons skilled in the art upon reference
to the description of the invention. It is, therefore, contemplated
that such modifications can be made without departing from the
spirit or scope of the present invention as defined.
* * * * *