WO2023126075A1

WO2023126075A1 - Heat exchange arrangement

Info

Publication number: WO2023126075A1
Application number: PCT/EP2022/050020
Authority: WO
Inventors: Fadil AYAD; Ying Dong
Original assignee: Huawei Technologies Co Ltd
Current assignee: Huawei Technologies Co Ltd
Priority date: 2022-01-03
Filing date: 2022-01-03
Publication date: 2023-07-06
Anticipated expiration: 2024-07-03
Also published as: CN118511045A

Abstract

A heat exchange arrangement (1) comprising a first fluid circuit (2) extending between an inlet manifold (3) and an outlet manifold (4) and a second fluid circuit (5). A main heat exchange structure (6) comprises spaced conduits (7) forming sections of said first fluid circuit (2), and gaps (8) between said conduits (7) form sections of said second fluid circuit (5). Several fluid return structures (9) interconnect adjacent conduits (7), each fluid return structure (9) being arranged at a first side (A) or a second side (B) of said main heat exchange structure (6). The inlet manifold (3) and said outlet manifold (4) are arranged at said first side (A), separated by one fluid return structure (9), or said inlet manifold (3) is arranged at said first side (A) and said outlet manifold (4) is arranged at said second side (B), separated by said main heat exchange structure (6).

Description

HEAT EXCHANGE ARRANGEMENT

TECHNICAL FIELD

The disclosure relates to a heat exchange arrangement comprising a first fluid circuit configured to accommodate a first fluid, said first fluid circuit extending between an inlet manifold and an outlet manifold and a second fluid circuit configured to accommodate a second fluid.

BACKGROUND

Heat pump systems are becoming mainstream technology for electric vehicles, used to heat up the vehicle cabin in efficient way. Heat pump systems can work at least in two modes, a cooling mode and a heating mode.

During the cooling mode, the vehicle cabin is cooled down. For this purpose, heat is absorbed from the cabin and rejected to the ambient through an air-cooled gas cooler. In order to improve the efficiency of the system, the refrigerant’s ability to cool can be enhanced by using a Liquid Cooled Gas Cooler (LCGC) acting as a pre-cooler. In this case, the refrigerant is partially cooled through the LCGC and subsequently directed to the air-cooled gas cooler to generate vehicle cooling. During the heating mode, LCGC can be used to instead warm up a coolant which in turn heats up the vehicle cabin via another heat exchanger, called heater core, exchanging heat between cold air and hot coolant.

Currently, the overwhelming majority of automotive heat pump systems use synthetic refrigerants such as R134a or R1234yf. However, there are other refrigerants offering significantly higher heating capacity than these synthetic refrigerants.

One of the challenges of using such refrigerants is that they are used under high pressure, reaching an operating pressure of 140 bar while the components of the system must withstand pressures up to 340 bar. This requires a general redesign of the conventional automotive refrigeration components.

For example, in known solutions, the refrigerant inlet and outlet manifold share conductive components. Since there is a substantial temperature difference between the refrigerant inlet and outlet temperatures, heat is conducted from the inlet manifold to the outlet manifold, heating the heat exchanger and degrading its performance.

Hence, there is a need for an improved heat exchanger assembly.

SUMMARY

It is an object to provide an improved heat exchange arrangement. The foregoing and other objects are achieved by the features of the independent claims. Further implementation forms are apparent from the dependent claims, the description, and the figures.

According to a first aspect, there is provided heat exchange arrangement comprising a first fluid circuit configured to accommodate a first fluid, the first fluid circuit extending between an inlet manifold and an outlet manifold, a second fluid circuit configured to accommodate a second fluid, a main heat exchange structure comprising a plurality of spaced conduits configured to form sections of the first fluid circuit, gaps between the conduits being configured to form sections of the second fluid circuit, at least three fluid return structures, each fluid return structure being configured to interconnect adjacent conduits, at least one of the fluid return structures being arranged at a first side of the main heat exchange structure and at least two of the fluid return structures being arranged at a second side of the main heat exchange structure, wherein the inlet manifold and the outlet manifold are arranged at the first side of the main heat exchange structure such that the inlet manifold and the outlet manifold are separated by one of the fluid return structures, or the inlet manifold is arranged at the first side of the main heat exchange structure and the outlet manifold is arranged at the second side of the main heat exchange structure, such that the inlet manifold and the outlet manifold are separated by the main heat exchange structure.

This solution facilitates a heat exchange arrangement which is not only flexible and can be easily adapted to, e.g., a vehicle manufacturer’s specifications, but which also experiences minimal heat transfer between refrigerant inlet manifold and outlet manifold, improving the performance of the heat exchanger.

In a possible implementation form of the first aspect, the conduits are arranged as an m x n matrix, the m x n matrix comprising m rows of conduits and n columns of conduits, preferably at least one row and at least two columns, allowing the heat exchange arrangement to have any suitable configuration.

In a possible implementation form of the first aspect, the conduits are formed by tubes, each column of the m x n matrix being formed by n stacked tubes, each pair of adjacent tubes being separated by a finned structure configured to facilitate the gaps and to allow flow of the second fluid. This facilitates a stable structure providing improved heat transfer for the second fluid.

In a possible implementation form of the first aspect, each pair of adjacent columns are separated by plates that are non-permeable to the second fluid, allowing the second fluid to be evenly distributed across the main heat exchange structure and, hence, heat exchange to be maximally efficient.

In a possible implementation form of the first aspect, the fluid return structure comprises a first element having at least two sets of openings, a first set of openings being configured to interconnect with a first column of the conduits, the first set of conduits being configured to allow flow in a first direction within the main heat exchange structure, and a second set of openings being configured to interconnect with a second column of the conduits, the second column of conduits being configured to allow flow in a second direction within the main heat exchange structure. This allows a simple and efficient solution for changing the flow direction, which also has a small form factor such that the size of the heat exchange arrangement is kept as small as possible.

In a possible implementation form of the first aspect, the fluid return structure further comprises a second element configured to redirect the flow of the first fluid from the first set of openings to the second set of openings. This allows a simple and efficient solution for changing the flow direction, which not only has a small form factor but is also easy to manufacture and assemble.

In a possible implementation form of the first aspect, the second element comprises a plurality of recesses configured to overlap the first set of openings and the second set of openings, providing a simple and efficient solution for changing the flow direction which requires a minimum of manufacturing steps. In a possible implementation form of the first aspect, the first element comprises a first plate provided with first set of openings and the second set of openings, and the second element comprises a second plate provided with the plurality of grooves, the first plate and the second plate being arranged in direct abutment, facilitating a very small form factor allowing the size of the heat exchange arrangement to be kept as small as possible.

In a possible implementation form of the first aspect, the at least two fluid return structures arranged at the second side of the main heat exchange structure are arranged adjacent each other, one of the fluid return structures being configured to redirect the flow of the first fluid from the first column of conduits to the second column of conduits, and the other of the fluid return structures being configured to redirect the flow of the first fluid from a third column of conduits to a fourth column of conduits, facilitating a change of flow direction at least twice within the heat exchange arrangement.

In a possible implementation form of the first aspect, the fluid return structure arranged at the first side of the main heat exchange structure is configured to redirect the flow of the first fluid from the second column of conduits to the third column of conduits, facilitating a three-time change of flow direction within the heat exchange arrangement which, for many applications, provides a sufficiently efficient as well as sufficiently small hear exchanger.

In a possible implementation form of the first aspect, the first fluid is a compressible gas, facilitating a significantly higher heating capacity for the heat exchange arrangement.

In a possible implementation form of the first aspect, the compressible gas has a maximum operating pressure of 140 bar and/or a maximum temperature of 150 C°, allowing the heat exchange to be highly efficient.

In a possible implementation form of the first aspect, the second fluid is a liquid mixture, allowing use of conventional vehicle heating and cooling units in addition to the heat exchange arrangement.

In a possible implementation form of the first aspect, the first fluid is a gaseous refrigerant and the second fluid is a liquid, facilitating a significantly higher heating capacity for the heat exchange arrangement. In a possible implementation form of the first aspect, the refrigerant is R-744 and the liquid is a water and glycol mixture, providing what is considered a more eco-friendly and less dangerous solution than when using conventional synthetic refrigerants.

In a possible implementation form of the first aspect, the first fluid has an inlet temperature T1 when in the inlet manifold, the first fluid has an outlet temperature T2 when in the outlet manifold, and a temperature difference AT between the inlet temperature T1 and the outlet temperature T2 is 50< AT <120 C°, facilitating a high heat exchange capacity.

In a possible implementation form of the first aspect, an average temperature difference between the first fluid and the second fluid is 10< AT2 <60 C°, facilitating a high heat exchange capacity.

In a possible implementation form of the first aspect, the heat exchange arrangement further comprises a header plate configured to support the tubes of the main heat exchange structure, the header plate comprising a plurality of throughgoing openings, each opening being configured to accommodate one tube, providing a support structure having a small form factor.

In a possible implementation form of the first aspect, the header plate comprises an m x n matrix of throughgoing openings, a first peripheral column of openings being configured to be fluidly connected to the inlet manifold, a second peripheral column of openings being configured to be fluidly connected to the outlet manifold, any intermediate column(s) of openings being configured to be fluidly connected to one of the first set of openings and the second set of openings of the fluid return structure, providing a support structure having a small form factor and which corresponds to the exact configuration of conduits.

These and other aspects will be apparent from the embodiments described below.

BRIEF DESCRIPTION OF THE DRAWINGS

In the following detailed portion of the present disclosure, the aspects, embodiments, and implementations will be explained in more detail with reference to the example embodiments shown in the drawings, in which: Fig. 1 shows a perspective view of a heat exchange arrangement in accordance with an example of the embodiments of the disclosure;

Fig. 2 shows a partial perspective view of one side of a heat exchange arrangement in accordance with an example of the embodiments of the disclosure, the side comprising two fluid return structures arranged coplanarly;

Fig. 3a shows a partial perspective view of a heat exchange arrangement in accordance with an example of the embodiments of the disclosure;

Fig. 3b shows an exploded view of the example show in Fig. 3a;

Fig. 4 shows a partial perspective view of the finned structure of a heat exchange arrangement in accordance with an example of the embodiments of the disclosure;

Fig. 5 illustrates the extent of the fluid circuits within a heat exchange arrangement in accordance with an example of the embodiments of the disclosure.

DETAILED DESCRIPTION

The present invention relates to a heat exchange arrangement 1 comprising a first fluid circuit

2 configured to accommodate a first fluid, the first fluid circuit 2 extending between an inlet manifold 3 and an outlet manifold 4, a second fluid circuit 5 configured to accommodate a second fluid, a main heat exchange structure 6 comprising a plurality of spaced conduits 7 configured to form sections of the first fluid circuit 2, gaps 8 between the conduits 7 being configured to form sections of the second fluid circuit 5, at least three fluid return structures 9, each fluid return structure 9 being configured to interconnect adjacent conduits 7, and at least one of the fluid return structures 9 being arranged at a first side A of the main heat exchange structure 6 and at least two of the fluid return structures 9 being arranged at a second side B of the main heat exchange structure 6. The inlet manifold 3 and the outlet manifold 4 are arranged at the first side A of the main heat exchange structure 6 such that the inlet manifold 3 and the outlet manifold 4 are separated by one of the fluid return structures 9, or the inlet manifold 3 is arranged at the first side A of the main heat exchange structure 6 and the outlet manifold 4 is arranged at the second side B of the main heat exchange structure 6, such that the inlet manifold

3 and the outlet manifold 4 are separated by the main heat exchange structure 6.

As illustrated in Fig 5, the heat exchange arrangement 1 comprises a first fluid circuit 2 configured to accommodate a first fluid and a second fluid circuit 5 configured to accommodate a second fluid. The solid line arrows illustrate the flow of the first fluid circuit 2 as it meanders back and forth across the main heat exchanged structure 6 and the turns in the fluid return structures 9. The dashed line arrows illustrate the flow of the second fluid circuit 5 as it travels from one side of the main heat exchanged structure 6 to the other.

The first fluid may be a compressible gas, and the compressible gas may have a maximum operating pressure of 140 bar and/or a maximum temperature of 150 C°. The first fluid may be a gaseous refrigerant, for example R-744 (CO2).

The second fluid may be a liquid, for example a liquid mixture such as a water and glycol mixture.

The first fluid circuit 2 extends between an inlet manifold 3 and an outlet manifold 4. The first fluid may have an inlet temperature T1 when in the inlet manifold 3 and an outlet temperature T2 when in the outlet manifold 4. The temperature difference AT between the inlet temperature T1 and the outlet temperature T2 may be 50< AT <120 C°.

An average temperature difference between the first fluid and the second fluid may be 10< AT2 <60 C°.

The main heat exchange structure 6, shown in more detail in Fig. 3b, comprises a plurality of spaced conduits 7 configured to form sections of the first fluid circuit 2, allowing the first fluid to flow therethrough.

The conduits 7 are spaced such that gaps 8 are formed between the conduits 7, the gaps 8 being configured to form sections of the second fluid circuit 5, allowing the second fluid to flow therethrough.

The conduits 7 may be arranged as an m x n matrix, the m x n matrix comprising m rows of conduits 7 and n columns of conduits 7, preferably at least one row and at least two columns. For example, Fig. 3b shows twelve rows and four columns.

The conduits 7 may be formed by tubes, such that each column of the m x n matrix is formed by n stacked tubes, and each pair of adjacent tubes is separated by a finned structure 10 configured to facilitate the gaps 8 and to allow flow of the second fluid. The finned structure 10, which is shown in more detail in Fig. 4, improves heat transfer for the second fluid by increasing the heat transfer surface as well as the convection heat transfer coefficient.

Furthermore, each pair of adjacent columns may be separated by plates 11 that are non- permeable to the second fluid. This allows the second fluid circuit 5 to be subdivided as it travels through the main heat exchange structure 6.

At least three fluid return structures 9 are provided, each fluid return structure 9 being configured to interconnect adjacent conduits 7 such that the first fluid can flow from one set of conduits 7 having a first flow direction to a second set of conduits having a second flow direction. Each fluid return structure 9 may redirect the first fluid circuit 2 such that the first fluid flows in opposite directions within the main heat exchange structure 6. In other words, the fluid return structure 9 is used to change the direction of flow of the first fluid.

Each fluid return structure 9 may be configured to interconnect the conduits 7 of one column to corresponding conduits 7 of a directly adjacent column, as illustrated in Fig. 3b.

At least one of the fluid return structures 9 is arranged at a first side A of the main heat exchange structure 6 and at least two of the fluid return structures 9 are arranged at a second side B of the main heat exchange structure 6, the first side A and second side B being shown in Figs. 1 and 3a.

The fluid return structure 9 may comprise a first element 12 having at least two sets of openings 13. A first set of openings 13a is configured to interconnect with a first column of the conduits 7 a, i.e., the first column of conduits 7a is configured to allow flow in a first direction DI within the main heat exchange structure 6, as shown in Fig. 3a. A second set of openings 13b are configured to interconnect with a second column of the conduits 7b, i.e., the second column of conduits 7b is configured to allow flow in a second direction D2 within the main heat exchange structure 6. The fluid return structure 9 may, in other words, allow redirection of the first fluid after exiting the first column of conduits 7a and before entering the second column of the conduits 7b. The fluid return structure 9 may further comprise a second element 14 configured to redirect the flow of the first fluid from the first set of openings 13a to the second set of openings 13b. The second element 14 may comprise a plurality of recesses 15 configured to overlap the first set of openings 13a and the second set of openings 13b.

The first element 12 may comprise a first plate provided with the first set of openings 13a and the second set of openings 13b, and the second element 14 may comprise a second plate provided with the plurality of grooves 15, the first plate and the second plate being arranged in direct abutment.

The at least two fluid return structures 9 arranged at the second side B of the main heat exchange structure 6 may be arranged adjacent each other, such that one of the fluid return structures 9 is configured to redirect the flow of the first fluid from the first column of conduits 7a to the second column of conduits 7b. Similarly, the other of the fluid return structures 9 may be configured to redirect the flow of the first fluid from a third column of conduits 7c to a fourth column of conduits 7d.

Correspondingly, the fluid return structure 9 arranged at the first side A of the main heat exchange structure 6 may be configured to redirect the flow of the first fluid from the second column of conduits 7b to the third column of conduits 7c. Hence, all columns of conduits 7a to 7b are interconnected by means of the fluid return structures 9, forming the first fluid circuit 2.

The heat exchange arrangement 1 may further comprise a header plate 16 configured to support the tubes of the main heat exchange structure 6. The header plate 16 comprises a plurality of throughgoing openings 17, each opening 17 being configured to accommodate one tube.

The header plate 16 may comprise an m x n matrix of throughgoing openings 17, corresponding to the m x n matrix of rows and columns of conduits 7. A first peripheral column of openings 17a is configured to be fluidly connected to the inlet manifold 3 and a second peripheral column of openings 17b is configured to be fluidly connected to the outlet manifold 4. Any suitable number of intermediate columns of openings 17c are configured to be fluidly connected to one of the first set of openings 13a and the second set of openings 13b of the fluid return structure 9. As shown in Fig. 3a, the inlet manifold 3 and the outlet manifold 4 may both be arranged at the first side A of the main heat exchange structure 6 such that the inlet manifold 3 and the outlet manifold 4 are separated by one of the fluid return structures 9.

As shown in Fig. 1, the inlet manifold 3 may be arranged at the first side A of the main heat exchange structure 6 and the outlet manifold 4 may be arranged at the second side B of the main heat exchange structure 6 such that the inlet manifold 3 and the outlet manifold 4 are separated by the main heat exchange structure 6.

The various aspects and implementations have been described in conjunction with various embodiments herein. However, other variations to the disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed subject-matter, from a study of the drawings, the disclosure, and the appended claims. In the claims, the word “comprising” does not exclude other elements or steps, and the indefinite article “a” or “an” does not exclude a plurality. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measured cannot be used to advantage.

The reference signs used in the claims shall not be construed as limiting the scope. Unless otherwise indicated, the drawings are intended to be read (e.g., cross-hatching, arrangement of parts, proportion, degree, etc.) together with the specification, and are to be considered a portion of the entire written description of this disclosure. As used in the description, the terms “horizontal”, “vertical”, “left”, “right”, “up” and “down”, as well as adjectival and adverbial derivatives thereof (e.g., “horizontally”, “rightwardly”, “upwardly”, etc.), simply refer to the orientation of the illustrated structure as the particular drawing figure faces the reader. Similarly, the terms “inwardly” and “outwardly” generally refer to the orientation of a surface relative to its axis of elongation, or axis of rotation, as appropriate.

Claims

1. A heat exchange arrangement (1) comprising

-a first fluid circuit (2) configured to accommodate a first fluid, said first fluid circuit (2) extending between an inlet manifold (3) and an outlet manifold (4);

-a second fluid circuit (5) configured to accommodate a second fluid;

-a main heat exchange structure (6) comprising a plurality of spaced conduits (7) configured to form sections of said first fluid circuit (2), gaps (8) between said conduits (7) being configured to form sections of said second fluid circuit (5);

-at least three fluid return structures (9), each fluid return structure (9) being configured to interconnect adjacent conduits (7), at least one of said fluid return structures (9) being arranged at a first side (A) of said main heat exchange structure (6) and at least two of said fluid return structures (9) being arranged at a second side (B) of said main heat exchange structure (6); wherein

-said inlet manifold (3) and said outlet manifold (4) are arranged at said first side (A) of said main heat exchange structure (6) such that said inlet manifold (3) and said outlet manifold (4) are separated by one of said fluid return structures (9); or

-said inlet manifold (3) is arranged at said first side (A) of said main heat exchange structure (6) and said outlet manifold (4) is arranged at said second side (B) of said main heat exchange structure (6), such that said inlet manifold (3) and said outlet manifold (4) are separated by said main heat exchange structure (6).

2. The heat exchange arrangement (1) according to claim 1, wherein said conduits (7) are arranged as an m x n matrix, said m x n matrix comprising m rows of conduits (7) and n columns of conduits (7), preferably at least one row and at least two columns.

3. The heat exchange arrangement (1) according to claim 2, wherein said conduits (7) are formed by tubes, each column of said m x n matrix being formed by n stacked tubes, each pair of adjacent tubes being separated by a finned structure (10) configured to facilitate said gaps (8) and to allow flow of said second fluid.

4. The heat exchange arrangement (1) according to any one of the previous claims, wherein each pair of adjacent columns separated by plates (11) that are non-permeable to said second fluid.

5. The heat exchange arrangement (1) according to any one of the previous claims, wherein said fluid return structure (9) comprises a first element (12) having at least two sets of openings (13), a first set of openings (13a) being configured to interconnect with a first column of said conduits (7a), said first set of conduits (7a) being configured to allow flow in a first direction (DI) within said main heat exchange structure (6), and a second set of openings (13b) being configured to interconnect with a second column of said conduits (7b), said second column of conduits (7b) being configured to allow flow in a second direction (D2) within said main heat exchange structure (6).

6. The heat exchange arrangement (1) according to claim 5, wherein said fluid return structure (9) further comprises a second element (14) configured to redirect the flow of said first fluid from said first set of openings (13a) to said second set of openings (13b).

7. The heat exchange arrangement (1) according to claim 6, wherein said second element (14) comprises a plurality of recesses (15) configured to overlap said first set of openings (13a) and said second set of openings (13b).

8. The heat exchange arrangement (1) according to claims 6 and 7, wherein said first element (12) comprises a first plate provided with said first set of openings (13a) and said second set of openings (13b), and said second element (14) comprises a second plate provided with said plurality of grooves (15), said first plate and said second plate being arranged in direct abutment.

9. The heat exchange arrangement (1) according to any one of claims 5 to 8, wherein said at least two fluid return structures (9) arranged at said second side (B) of said main heat exchange structure (6) are arranged adjacent each other, one of said fluid return structures (9) being configured to redirect the flow of said first fluid from said first column of conduits (7a) to said second column of conduits (7b), and the other of said fluid return structures (9) being configured to redirect the flow of said first fluid from a third column of conduits (7c) to a fourth column of conduits (7d).

10. The heat exchange arrangement (1) according to claim 9, wherein said fluid return structure (9) arranged at said first side (A) of said main heat exchange structure (6) is configured to redirect the flow of said first fluid from said second column of conduits (7b) to said third column of conduits (7c).

11. The heat exchange arrangement (1) according to any one of the previous claims, wherein said first fluid is a compressible gas.

12. The heat exchange arrangement (1) according to claim 11, wherein said compressible gas has a maximum operating pressure of 140 bar and/or a maximum temperature of 150 C°.

13. The heat exchange arrangement (1) according to any one of the previous claims, wherein said second fluid is a liquid mixture.

14. The heat exchange arrangement (1) according to any one of the previous claims, wherein said first fluid is a gaseous refrigerant and said second fluid is a liquid.

15. The heat exchange arrangement (1) according to claim 14, wherein said refrigerant is R- 744 and said liquid is a water and glycol mixture.

16. The heat exchange arrangement (1) according to any one of the previous claims, wherein said first fluid has an inlet temperature T1 when in said inlet manifold (3), said first fluid has an outlet temperature T2 when in said outlet manifold (4), and a temperature difference AT between said inlet temperature T1 and said outlet temperature T2 is 50< AT <120 C°.

17. The heat exchange arrangement (1) according to any one of the previous claims, wherein an average temperature difference between said first fluid and said second fluid is 10< AT2 <60 r'o

18. The heat exchange arrangement (1) according to any one of claims 3 to 17, further comprising a header plate (16) configured to support said tubes of said main heat exchange structure (6), said header plate (16) comprising a plurality of throughgoing openings (17), each opening (17) being configured to accommodate one tube.

19. The heat exchange arrangement (1) according to claim 18, wherein said header plate (16) comprises an m x n matrix of throughgoing openings (17), a first peripheral column of openings (17a) being configured to be fluidly connected to said inlet manifold (3), a second peripheral column of openings (17b) being configured to be fluidly connected to said outlet manifold (4), any intermediate column(s) of openings (17c) being configured to be fluidly connected to one of said first set of openings (13a) and said second set of openings (13b) of said fluid return structure (9).