Dual Pass Cooling Coil Fin Density Optimization
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Solution Overview
Problem
Current dual-pass opposed flow cooling coils with uniform Finned Media Configuration across both counter and parallel sections suffer from higher air pressure drop in the parallel-flow pass, which negatively impacts overall thermal performance and increases fan power requirements.
Innovation Solution
Optimizing the Finned Media Configuration by increasing its density only in the counter-flow passes and reducing or eliminating it in the parallel-flow passes, thereby shifting the benefits of reduced pressure drop to the counter-flow sections where heat transfer is more effective.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If uniform Finned Media Configuration is used across both counter and parallel sections, then manufacturing is simplified, but air pressure drop increases in the parallel-flow pass reducing overall thermal performance
Solution Approach 1:
The patent applies different fin density configurations to different sections of the heat exchanger. The counter-flow pass uses higher fin density to maximize heat transfer where pressure drop is less critical, while the parallel-flow pass uses lower or no fins to minimize air pressure drop. This local differentiation resolves the contradiction by optimizing each section for its specific functional requirements rather than using uniform configuration throughout.
2Temperature
If fin density is increased to improve heat transfer, then thermal performance improves, but air pressure drop increases requiring higher fan power
Solution Approach 1:
The patent strategically places higher fin density only in the counter-flow pass where heat transfer is most effective and pressure drop has less impact on overall system performance. The parallel-flow pass uses reduced or zero fin density to minimize air resistance and fan power requirements. This localized optimization allows the system to achieve good heat transfer performance without the penalty of high pressure drop throughout the entire heat exchanger.
Solution Approach 2:
The heat exchanger is divided into distinct counter-flow and parallel-flow passes, allowing independent optimization of fin density in each section. This segmentation enables the system to maximize heat transfer in the counter-flow section while minimizing pressure drop in the parallel-flow section, thereby optimizing the balance between thermal performance and fan power consumption.
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 approach enhances thermal performance while significantly reducing air pressure drop, resulting in a minimum 10% reduction in fan power needed to move air through the system, improving overall efficiency and thermal performance.
Implementation Method 1
Finned-tube coils used for air cooling and dehumidifying
Implementation Method 2
air cooling and dehumidifying
Implementation Method 3
refrigerant cooling coils
Data Source
AI summary
A dual pass heat exchanger for cooling and dehumidifying an airstream has adjacent passes for air flow in which air flow is in opposite directions being counter-flow and parallel-flow passes. A cooling coil contains flowing chilled liquid refrigerant extending through all of the passes, and the coiling coil has fins on outer surfaces thereof for promoting efficient thermal transfer, whereby density of the fins in the counter-flow passes is greater than density in the parallel-flow passes, whereby fin density is varied in fin style, locational density, thickness and/or depth.