Angled-Slab Condenser Design for Even Air Flow Distribution in HVAC
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Solution Overview
Problem
Existing condenser systems in HVAC systems experience uneven air flow distribution across heat exchanger coils, leading to inefficient cooling of refrigerant due to the arrangement of slabs, resulting in varying cooling performance across different sections.
Innovation Solution
The condenser module incorporates heat exchanger slabs oriented at acute angles relative to each other, with the second slab having a greater height and surface area than the first slab, allowing for even air flow distribution and increased refrigerant flow, compensating for reduced air flow rates across the second slab.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If heat exchanger slabs are arranged in a conventional parallel configuration, then the structure is simple and easy to manufacture, but the air flow distribution across different sections becomes uneven, leading to varying cooling performance
Solution Approach 1:
The patent applies asymmetry by orienting the second heat exchanger slab at an acute angle (e.g., 30-60 degrees) relative to the first slab, rather than using a conventional parallel arrangement. This asymmetric configuration fundamentally changes the air flow pattern across the slabs, enabling more uniform distribution of ambient air across all heat exchanger surfaces and eliminating the uneven cooling performance issue while maintaining manufacturing feasibility.
2Reliability
If the second slab is oriented at an acute angle and has greater height, then even air flow distribution and cooling effectiveness are achieved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent applies local quality by making the second slab different from the first slab in specific ways: it is oriented at an acute angle and has a greater height (e.g., 1.5-2 times the height of the first slab). This localized differentiation in orientation and dimensions allows each slab to be optimized for its specific position in the air flow path, achieving uniform cooling effectiveness across all sections while avoiding unnecessary overall system complexity.
3Reliability
If slabs are arranged to accommodate varying air flow rates, then cooling uniformity is improved, but the surface area requirements and system size increase
Solution Approach 1:
The patent applies parameter changes by modifying the orientation angle and height dimensions of the heat exchanger slabs. Specifically, the second slab is rotated to an acute angle and its height is increased (e.g., 1.5-2 times the first slab height). These parameter changes optimize the surface area utilization and air flow distribution, achieving uniform cooling effectiveness without requiring excessive total surface area, as the configuration allows more efficient use of the available heat exchanger surfaces.
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
This configuration ensures more even cooling of refrigerant across all slabs, improving the overall efficiency and performance of the condenser by maintaining similar cooling effectiveness despite varying air flow rates, and reducing pressure drops within the system.
Implementation Method 1
Ambient air may be delivered across the coils to cool the working fluid, thereby enabling the working air to absorb heat from the conditioning fluid to cool the conditioning fluid
Implementation Method 2
a condenser having coils through which working fluid may flow. Ambient air may be delivered across the coils to cool the working fluid
Data Source
AI summary
A condenser module of a heating, ventilation, and/or air conditioning (HVAC) system includes a first slab having a first plurality of tubes configured to receive a refrigerant from a compressor of the HVAC system. The first plurality of tubes is arrayed along a first dimension of the first slab. The condenser module also includes a second slab that has a second plurality of tubes configured to receive the refrigerant from the compressor. The second plurality of tubes is arrayed along a second dimension of the second slab, the second slab is oriented at an acute angle relative to the first slab, and the second dimension is greater than the first dimension.