Condenser Turbulator Panels for Independent Dual-Fluid Flow Control
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Solution Overview
Problem
Existing heat exchangers, such as plate heat exchangers, face challenges in independently shaping flow paths for gaseous and liquid media due to shared extrusion patterns, which limits efficient heat exchange and flow control between media with different physical properties, particularly in condensation processes where separate flow management is necessary to reduce flow rates and introduce turbulence while maintaining low pressure drops.
Innovation Solution
A heat exchanger design featuring differently shaped turbulator panels for the refrigerant and coolant circuits, with distinct wave-shaped and notched elements respectively, allows for independent configuration of flow paths to optimize flow rate reduction and turbulence introduction, ensuring efficient heat exchange between gaseous refrigerants and liquid coolants while maintaining low pressure drops.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the same extrusion pattern is used for both refrigerant and coolant circuits, then manufacturing is simplified, but independent flow path optimization is lost
Solution Approach 1:
The heat exchanger is divided into two independent plate sets: first plates forming the refrigerant circuit with first extrusion patterns, and second plates forming the coolant circuit with second extrusion patterns. This segmentation allows each circuit to be optimized independently for its specific fluid dynamics requirements while maintaining separate channel systems that can be tailored to the unique flow characteristics of refrigerant versus coolant.
2Adaptability or versatility
If separate extrusion patterns are used for refrigerant and coolant circuits, then flow path optimization is improved, but manufacturing complexity increases
Solution Approach 1:
While maintaining separate extrusion patterns for optimal flow control, the first and second plates are merged into a single integrated heat exchanger assembly with interleaved channel systems. The refrigerant circuit plates and coolant circuit plates are alternately arranged and connected through common end plates and sealing structures, combining two optimized circuits into one compact unit that achieves both flow optimization and manufacturing efficiency.
3Productivity
If flow rate reduction and turbulence introduction are optimized, then heat exchange efficiency is improved, but pressure drop increases
Solution Approach 1:
Different extrusion patterns are applied to different plate sets based on the specific flow requirements of each circuit. The first extrusion patterns on refrigerant circuit plates are optimized for gas flow characteristics with appropriate turbulence generation, while the second extrusion patterns on coolant circuit plates are optimized for liquid flow characteristics. This localized optimization allows each circuit to achieve efficient heat transfer with minimal unnecessary pressure drop.
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 design enhances heat exchange efficiency by allowing independent shaping of flow paths for each medium, optimizing flow disturbances and pressure drops, thereby improving the performance of heat exchangers in air conditioning systems, particularly for gaseous refrigerants and liquid coolants like water or glycol.
Implementation Method 1
the turbulator panel serves at the same time for reinforcing of the structure between the end plates, as well as it is an obstacle to the flow of the refrigerant and causes a decrease in the flow rate and its interfering resulting in releasing of the liquid phase
Implementation Method 2
resulting in better heat transfer between the media
Implementation Method 3
Heat exchanger, in particular a condenser, for use inter alia in automobile air conditioning systems
Implementation Method 4
in the case of a heat exchanger in which the heat emitting refrigerant is a gas changing its physical state to a liquid as a result of the cooling
Data Source
Figure 1~2
Figure 3~5
Figure 6~8
AI summary
Heat exchanger, in particular condenser, comprises two parallel end closing plates (1, 2) having made a coolant inlet and outlet and at least one inlet and an outlet of the refrigerant. A heat exchange unit is provided between the closing plates (1, 2) and at least one coolant compartment and at least one refrigerant compartment, separated by an inner plate (5). The coolant compartments and refrigerant compartments are arranged alternately and connected such that they form together with said inlets and outlets separated hydraulic circuits for the coolant and refrigerant and a turbulator panel (3, 4) is arranged in each of the compartments (3, 4). The turbulator panels (3) of the refrigerant circuit comprise on their surface first disturbing elements (9) the shape of which is matched to the physical properties of the gaseous refrigerant, and which determine the height of the turbulator panel of the refrigerant circuit, while the turbulator panels (4) of the coolant circuit comprise on their surface second disturbing elements (10) the shape of which is matched to the physical properties of the liquid coolant which determine the height of the turbulator panel of the coolant circuit, wherein the shape of the first disturbing elements (9) is different from the shape of the second disturbing elements (10). The shape of the turbulator panels (3, 4) is matched to the independent optimal managing, slowing down and disturbing of the refrigerant and the coolant, while ensuring a low pressure drop of their flow to achieve a high heat exchange coefficient.