Coil Heat Exchanger Layout With Variable Radial Spacing
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Solution Overview
Problem
Existing heat exchangers for high-pressure cleaners are inefficient and costly to produce due to the need for specially designed spacers with precise positioning to enhance heat transfer, which complicates manufacturing and installation.
Innovation Solution
The heat exchanger design varies the radial distance between the outer and inner heating coils by deforming specific turns of the outer coil between spacers, allowing for a non-uniform radial distance that improves heat transfer efficiency without requiring precise spacer placement, using a pressing device to deform the outer coil into an oval shape with varying distances between spacers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If spacers with different radial indentations are used to arrange outer heating coil turns radially offset from one another, then heat transfer efficiency is improved, but manufacturing complexity and cost increase due to requiring many specially designed spacers with precise positioning
Solution Approach 1:
The patent applies local quality by creating non-uniform radial spacing of the outer heating coil only in specific sections between spacers, while maintaining uniform spacing in other areas. This localized variation in coil spacing optimizes heat transfer in critical regions without requiring complex spacers throughout the entire structure, thus improving heat transfer efficiency while controlling manufacturing complexity
Solution Approach 2:
Instead of using complex spacers to achieve radial offset as proposed in prior art, the patent inverts the approach by using simple identical spacers for positioning and achieving the radial offset effect through controlled deformation of the outer coil itself. This inversion simplifies the spacer design while maintaining the heat transfer benefits
2Ease of manufacture
If identical spacers are used for all positions of the outer heating coil, then manufacturing is simplified and costs are reduced, but heat transfer efficiency decreases due to uniform radial distance between coils
Solution Approach 1:
The patent applies dynamics by transforming the static, uniformly spaced outer heating coil into a dynamically varied configuration where sections of the coil are deliberately deformed to different radial positions. This dynamic variation in coil spacing allows identical spacers to be used while still achieving optimized heat transfer through regions of varying radial distance between inner and outer coils
Solution Approach 2:
The patent changes the radial distance parameter of the outer heating coil in specific sections between spacers, creating a non-uniform spacing pattern. This parameter variation optimizes heat transfer efficiency by allowing closer spacing where better thermal coupling is needed, while maintaining simpler spacer designs with identical specifications throughout
3Loss of energy
If the outer heating coil is deformed to create varying radial distance between turns, then heat transfer is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies self-service by allowing the outer heating coil to be deformed into the desired non-uniform configuration during the winding process itself, rather than requiring precise post-manufacturing adjustments. The coil is formed with varying radial distance inherent to the winding operation, enabling heat transfer optimization without demanding high precision in subsequent manufacturing steps
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 enhances heat transfer efficiency by varying the radial distance between the heating coils, allowing for improved swirling of heated air and increased heat transfer to the cleaning liquid, while simplifying the manufacturing process and reducing costs by using identical spacers and reducing thermal stresses.
Implementation Method 1
A heat transfer then takes place from the hot air via the heating coils to the liquid to be heated
Implementation Method 2
hot air flows around the heat exchanger... The cleaning liquid can flow through the heat exchanger. A heat transfer then takes place from the hot air via the heating coils to the liquid
Data Source
Figure 1
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AI summary
The invention relates to heat exchangers (20) for heating a liquid, in particular for high-pressure cleaners, comprising an inner and an outer heating winding (22, 24) which each have a plurality of turns, and comprising spacers (38, 39, 40, 41) which are disposed between the inner heating winding (22) and the outer heating winding (24) and distributed over the circumference of the inner heating winding (22). In order to modify the heat exchanger (20) in such a way that it can be produced cost-effectively and is very efficient, according to the invention at least one turn (55, 57) of the outer heating winding (24) comprises, between two spacers (40, 41) that are immediately adjacent to one another, a first turn section (64, 64a) in which the radial spacing from the inner heating winding (22) is less or greater than in the region of the spacers (40, 41). The invention further relates to two methods for producing such a heat exchanger (20).