Casting Block Cooling Tube with Turbulence Ribs for Heat Transfer
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Solution Overview
Problem
The heat transfer performance of tube coolers in electric vehicles is limited by the low heat transfer coefficient between the coolant and the tube due to smooth inner surfaces leading to less turbulence and thick flow boundary layers, resulting in inadequate thermal management of electrical components.
Innovation Solution
A casting block assembly with a tube having turbulence generating devices, such as ribs or dimples, is used to promote turbulence and reduce boundary layer thickness, enhancing the heat transfer coefficient between the coolant and the tube.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the tube has a smooth inner surface, then the manufacturing is easier and the flow resistance is lower, but the turbulence is reduced and the heat transfer coefficient becomes low
Solution Approach 1:
The tube surface is designed with different local properties: smooth in some regions and featuring protrusions or recesses in other regions. This local variation creates turbulence zones where needed while maintaining smooth sections for easy manufacturing and low flow resistance, thereby improving the heat transfer coefficient without sacrificing manufacturing ease
Solution Approach 2:
The tube incorporates a porous or textured inner surface structure with protrusions and recesses that create turbulence in the coolant flow. This textured surface structure enhances heat transfer while the overall tube design maintains manufacturability through conventional forming processes
2Temperature
If turbulence generating devices are added to the tube, then the heat transfer coefficient increases, but the device complexity increases
Solution Approach 1:
The turbulence generating features (protrusions and recesses) are integrated directly into the tube wall structure itself, merging the heat transfer enhancement function with the tube structure. This eliminates the need for separate turbulence generating devices, thereby reducing overall device complexity while maintaining enhanced heat transfer performance
Solution Approach 2:
The tube structure serves multiple functions simultaneously: it provides structural support, guides coolant flow, and generates turbulence through its integrated protrusions and recesses. This multi-functionality reduces the need for additional components, simplifying the overall device while improving heat transfer
3Temperature
If the tube has an elliptical cross-section, then the surface area increases and heat transfer is enhanced, but the manufacturing complexity increases
Solution Approach 1:
The tube cross-section is changed from a conventional circular shape to an elliptical shape, altering the geometric parameters to increase surface area for heat transfer. This parameter change enhances heat transfer performance while the elliptical geometry can be achieved through standard tube forming processes, limiting the increase in manufacturing complexity
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 turbulence generating devices increase turbulence intensity, reduce boundary layer thickness, and enhance heat transfer coefficient, improving thermal management of electrical components by increasing the surface area and flow speed while maintaining design flexibility.
Implementation Method 1
the tube has at least one turbulence generating device to promote turbulence inside the tube and reduce boundary layer thickness, and therefore increase the heat transfer coefficient between the coolant and the tube
Implementation Method 2
promote turbulence inside the tube and reduce boundary layer thickness
Implementation Method 3
increases the surface area of the tube, and therefore increases the surface area of the tube which is in contact with the coolant, while maintaining the same cross-sectional flow area, enhancing heat transfer
Data Source
AI summary
A heat dissipation structure for a casting block assembly, which includes a tube extending through a casting block, and the tube has at least one turbulence generating device to promote turbulence inside the tube and reduce boundary layer thickness, and therefore increase the heat transfer coefficient. The turbulence generating device is one or more ribs or dimples integrally formed as part of the tube, before forming the casting block around a portion of the tube. The ribs or dimples promote turbulence to reduce boundary layer thickness, and therefore increase the heat transfer coefficient. The turbulence generating devices promote higher turbulence intensity, a thinner boundary layer thickness, increased heat transfer coefficient, and a stronger bond between the tube and the casting block. The tube may have an elliptical cross-section, which allows for increased spacing between various portions of the tube while maintaining the same cross-sectional flow area, enhancing heat transfer.