Coil Key Separator for Heat Exchanger Vibration Damping
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Solution Overview
Problem
Heat exchangers in swimming pools and spas face issues with vibration and corrosion due to high water velocity and the use of corrosive chemicals, requiring costly materials and complex assembly methods to center and separate tube wraps for optimal operation.
Innovation Solution
The coil key separator device, with a unique curved shape, is inserted between tube wraps to lock them in place, minimizing vibration and corrosion, and can be easily installed without delay, using inexpensive plastic materials that withstand pool chemicals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If very thin wall tubing is used in heat exchangers to maximize heat transfer and minimize expense, then heat transfer efficiency is improved and cost is reduced, but the tubes become more susceptible to vibration damage and corrosion from high velocity water flow and corrosive chemicals
Solution Approach 1:
The patent introduces tube wraps as intermediary protective elements that surround the thin wall heat exchanger tubes. These wraps serve as a mediator between the corrosive environment (chlorine, high velocity water) and the vulnerable thin tubes, providing mechanical protection and corrosion resistance while allowing the thin walls to maintain their heat transfer efficiency
Solution Approach 2:
The patent employs composite construction by combining thin wall metal tubing with protective tube wraps made of corrosion-resistant materials. This composite structure allows the inner tube to provide heat transfer while the outer wrap provides protection against vibration and corrosion, creating a multi-functional assembly that addresses both efficiency and durability concerns
2Productivity
If high flow rate is used in heat exchangers to ensure adequate heat transfer, then heat transfer performance is improved, but vibration of the coils increases causing potential tube damage
Solution Approach 1:
The patent applies beforehand cushioning by installing tube wraps around the heat exchanger tubes before they are subjected to high velocity water flow. These pre-installed wraps act as a cushioning layer that absorbs and dampens vibration energy, preventing the high flow rate from causing damaging vibrations to the thin tube walls
Solution Approach 2:
The patent changes the physical state and protective properties of the tube surface by applying tube wraps, which modify the vibration characteristics and reduce the impact of high flow rate vibrations. This parameter change in the tube surface condition allows the system to tolerate higher flow rates without excessive vibration damage
3Manufacturing precision
If tube wraps are inserted between heat exchanger tubes to prevent vibration and center them, then tube positioning is improved, but assembly time and complexity increase
Solution Approach 1:
The patent applies preliminary action by pre-forming and pre-positioning the tube wraps around the heat exchanger tubes during manufacturing, rather than requiring complex assembly operations at the installation site. This preliminary preparation simplifies the final assembly process and reduces on-site time while ensuring precise tube positioning
Solution Approach 2:
The tube wraps are designed to be self-centering and self-positioning elements that automatically align with the heat exchanger tubes during assembly. This self-service characteristic eliminates the need for complex alignment procedures and manual positioning adjustments, significantly reducing assembly time while maintaining precision
4Reliability
If expensive alloy materials such as titanium or high alloy stainless steels are used to prevent corrosion from chlorine, then corrosion resistance is improved, but manufacturing cost increases
Solution Approach 1:
The patent employs cheaper alternative materials for the tube wraps, using corrosion-resistant materials that are less expensive than titanium or high alloy stainless steels. While individual wraps are replaceable, the cost-effective materials provide sufficient protection against chlorine corrosion, reducing overall manufacturing cost while maintaining adequate reliability
Solution Approach 2:
The patent uses composite material construction by combining affordable base materials with protective coatings or layered structures in the tube wraps. This composite approach provides corrosion resistance comparable to expensive alloys while using more cost-effective materials, achieving the desired corrosion protection at lower manufacturing 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
The device effectively dampens vibrations, prevents rubbing between tube wraps, and allows for quick assembly, reducing maintenance costs and ensuring optimal heat transfer performance.
Implementation Method 1
heat exchanger to be able to constantly work
Implementation Method 2
water flowing through the heat exchanger
Implementation Method 3
The coil key separator device effectively dampens vibrations
Implementation Method 4
using inexpensive plastic materials that withstand pool chemicals
Data Source
AI summary
A swimming pool, Spa or combination of a swimming pool or spa is heated with a heat pump and a heat exchanger. The heat exchanger comprises a water input, a water output, a heating agent input, a heating agent output, an inner coil and an outer coil being disposed about the outer periphery of the inner coil; and a separator device being configured and disposed to separate the coils in order to minimize vibrating and rubbing against each other. The separator device comprises a first separator device portion having two rounded shoulder portions configured to permit the separator device to be rotated into position between the inner coil and the outer coil, a middle portion comprising two substantially C-shaped curves, which substantially C-shaped curves form a dog bone-shape, and a second separator device portion comprising two rounded configured to be turned or twisted upon assembly of the heat exchanger.