Atomizing Disc Refrigerant Mixing for Frost-Free Evaporator Flow
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Solution Overview
Problem
Traditional refrigeration systems suffer from inefficient heat transfer and energy consumption due to the inefficient flow rate through the evaporator coil, leading to poor cooling efficiency and frost or ice buildup, especially in the initial lower portion of the coil.
Innovation Solution
An atomizing device is positioned between the expansion valve and the evaporator, utilizing a tubular structure with an atomizing means, such as a disc with angled blades, to enhance the vaporization of refrigerant, ensuring a higher vapor content and improved heat transfer efficiency by creating a spiral turbulent flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If refrigerant flows through the evaporator coil in traditional systems, then heat exchange occurs, but the flow rate is inefficient leading to poor cooling efficiency and frost buildup
Solution Approach 1:
The patent applies preliminary action by vaporizing the refrigerant before it enters the evaporator coil through the atomizing device. The refrigerant is atomized and mixed with warm air in a mixing chamber, ensuring proper vaporization occurs upstream. This preliminary vaporization prevents liquid refrigerant from reaching the evaporator, thereby preventing frost buildup while maintaining efficient heat exchange performance.
2Productivity
If refrigerant is vaporized before entering the evaporator, then heat transfer efficiency improves, but additional device complexity is introduced
Solution Approach 1:
The patent merges multiple functions into a single integrated atomizing device. The device combines the atomizing means, mixing chamber, and flow control functionality into one compact unit that fits within the existing refrigeration system between the expansion valve and evaporator. This merging approach achieves improved heat transfer efficiency while minimizing the increase in overall system complexity.
Solution Approach 2:
The patent introduces an intermediary mixing chamber that acts as a mediator between the expansion valve and the evaporator. The mixing chamber allows the atomized refrigerant to mix with warm air, facilitating gradual vaporization without requiring complex heating elements or multiple separate components. This intermediary approach simplifies the overall system while achieving the desired heat transfer improvement.
3Quantity of substance
If atomizing means is added to vaporize refrigerant, then vapor content increases, but manufacturing complexity increases
Solution Approach 1:
The patent achieves increased vapor content by changing the physical parameters of the refrigerant through atomization. The atomizing means breaks the liquid refrigerant into fine droplets, dramatically increasing the surface area for evaporation. This parameter change (from liquid to atomized spray) enables rapid vaporization and high vapor content in the refrigerant mixture without requiring complex manufacturing processes, as the atomizing device can be fabricated using standard manufacturing techniques.
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 solution achieves an efficiency enhancement of 8-15% and up to 20% by ensuring uniform flow and increased vaporization of refrigerant, reducing energy consumption and preventing frost buildup, thereby improving the overall cooling performance.
Implementation Method 1
The apparatus includes a tubular device and a means associated with the device for atomizing (or vaporizing) the refrigerant flowing into the device from the expansion valve
Implementation Method 2
The liquid in the evaporator is in an adiabatic state and therefore cannot absorb or reject heat
Data Source
AI summary
A method and apparatus to improve the efficiency of a heat exchange system comprising a compressor, condenser, expansion valve, an evaporator and an expansion valve are provided. The apparatus is positioned between the expansion valve and the evaporator and comprises an atomizing disc, an outer connector pipe and two inner pipes inside the connector pipe in contact with the disc. The disc is provided with vertical blades that are angled to provide the turbulence necessary to create a low pressure at the back of the disc. The low pressure thus created vaporizes the partially vaporized incoming refrigerant from the expansion valve and thereby improves the efficiency of the refrigeration system.