Chevron Corrugated Fin Water Drainage Heat Exchanger
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Solution Overview
Problem
High-frequency, low-amplitude corrugated fins in heat exchanger coil assemblies face issues with water retention and condensation in humid environments, leading to decreased heat exchange efficiency and potential water droplet carryover, which can cause operational shutdowns in environments like meat processing plants.
Innovation Solution
The design incorporates a plate member with alternating series of corrugated segments at different angles forming a chevron configuration, directing water accumulation towards the center for drainage, thereby reducing water retention on vertical edges and enhancing heat transfer efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-frequency, low-amplitude corrugated fins are used to increase heat exchange surface area, then heat exchange efficiency is improved, but water retention in corrugation valleys increases leading to decreased performance
Solution Approach 1:
The corrugated fin is segmented into multiple zones with different corrugation frequencies. The first zone has high-frequency corrugations for maximum heat exchange, while the second zone has lower-frequency corrugations that facilitate water drainage. This segmentation allows the fin to simultaneously achieve high heat exchange efficiency and effective water removal without requiring a complete redesign of the entire fin structure.
Solution Approach 2:
Different portions of the fin are given different local properties: the first zone (typically the leading or upper portion) features high-frequency corrugations optimized for heat transfer, while the second zone (trailing or lower portion) features lower-frequency corrugations optimized for water drainage. This local differentiation allows each zone to perform its specific function optimally while contributing to the overall system performance.
2Productivity
If corrugations are oriented horizontally to maximize surface area, then heat exchange capacity increases, but water accumulates in valleys creating liquid insulation layers
Solution Approach 1:
The fin design incorporates a dynamic water removal mechanism where the second zone's lower-frequency corrugations create a gradient that actively promotes water drainage. As water accumulates in the first zone, the geometric gradient toward the second zone facilitates natural drainage, creating a dynamic balance between water accumulation and removal that maintains heat exchange efficiency over time.
Solution Approach 2:
The design converts the potentially harmful effect of water accumulation into a beneficial drainage mechanism. The same corrugated structure that initially traps water is designed with a second zone where the corrugation geometry and orientation facilitate water flow and drainage, transforming the water retention problem into a controlled water removal system that actually enhances overall performance.
3Area of stationary object
If high-frequency corrugations are used throughout the fin, then surface area is maximized, but manufacturing complexity and cost increase
Solution Approach 1:
Instead of applying high-frequency corrugations to the entire fin surface, the design applies them only to the first zone where they are most needed for heat exchange. The second zone uses a simpler, lower-frequency corrugation pattern that is easier and less costly to manufacture. This partial application of the complex pattern achieves the necessary surface area for heat transfer while significantly reducing manufacturing complexity and cost.
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 effectively drains water accumulation, minimizing water build-up on the fin edges and within corrugations, maintaining heat exchange efficiency while preventing water carryover and ensuring compliance with regulatory standards.
Implementation Method 1
directing water accumulation towards the center for drainage
Implementation Method 2
heat is exchanged between the internal heat exchange fluid in the coil assembly 12 and air that is drawn through the coil assembly 12 by the blower 16
Implementation Method 3
air that is drawn through the coil assembly 12 by the blower 16
Implementation Method 4
the curved walls forming the corrugations 30 retain the water in the valleys as a result of the capillary action
Data Source
AI summary
A high-frequency, low-amplitude corrugated fin for a heat exchanger assembly includes a plate member that extends horizontally and vertically to define a reference plane. The plate member has a plurality of conduit portions, a first and second series of corrugated segments formed in the plate member. The first and second series of corrugated segments undulate generally equidistantly relative to and from the reference plane as viewed in cross-section. The plurality of conduit portions is inter-dispersed throughout the plate member among the first and second series of corrugated segments. Each one of the first series of corrugated segments extends at a first angle relative to horizontal and each one of the second series of corrugated segments extend at a second angle relative to horizontal such that individual adjacent ones of the first and second series of corrugated segments form at least a generally chevron-shaped configuration as viewed in plan view.