Double-V Stacked Heat Exchanger for Low Fan Power Cooling
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Solution Overview
Problem
Existing air-cooled heat exchangers face inefficiencies in heat transfer due to uneven air flow and require significant fan power to achieve desired cooling, especially when the temperature difference between the working fluid and incoming air is small.
Innovation Solution
A modular V-shaped heat exchange assembly with stacked modules and a fan module, featuring a bottom module with two heat exchangers in a V-shape, a top module continuing the V-shape, and a fan module on top, optimized for equal air flow and enhanced heat exchange capacity, optionally with adiabatic pads or spray nozzles for pre-cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If traditional air-cooled heat exchangers are used with standard configurations, then the structure is simple and easy to manufacture, but the air flow is uneven and fan power consumption is high
Solution Approach 1:
The heat exchanger is divided into multiple modular units, each containing a V-shaped bundle of tubes. These modules can be stacked vertically to form the complete heat exchanger assembly. This segmentation allows for optimized air flow patterns in each module while maintaining manufacturing simplicity through standardized module production.
Solution Approach 2:
The patent employs a V-shaped configuration for the tube bundles within each module, creating an asymmetric arrangement that promotes more uniform air flow distribution across the heat exchange surfaces. This asymmetric V-shape design prevents dead zones and improves overall heat transfer efficiency while reducing the power required by fans.
2Temperature
If the temperature difference between working fluid and incoming air is small, then the system can operate in warmer environments, but the air volume and fan horsepower required increase significantly
Solution Approach 1:
The patent utilizes vertical stacking of multiple heat exchange modules to add a vertical dimension to the heat exchange process. This allows for increased heat transfer area without proportionally increasing the horizontal footprint, enabling more effective heat removal even when temperature differences are small, thereby reducing the air volume and fan power required.
3Productivity
If more heat exchange area is provided to increase heat exchange capacity, then the heat transfer efficiency improves, but the device footprint and spacing requirements increase
Solution Approach 1:
The patent achieves increased heat exchange capacity by stacking modules vertically, utilizing the vertical dimension to multiply the effective heat transfer area. Multiple V-shaped tube bundles are arranged in vertical stacks, allowing significant heat exchange capacity to be achieved within a compact horizontal footprint, reducing both the device area and required spacing.
Solution Approach 2:
The patent combines multiple heat exchange modules into a single integrated assembly where modules share common structural elements and air flow paths. This merging allows the system to achieve high heat exchange capacity while minimizing redundant structures and optimizing the use of space, thereby reducing the overall footprint and spacing requirements.
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 solution provides higher fluid flow rates and greater heat exchange capacity with reduced fan power consumption, utilizing the same footprint and allowing for multiple configurations to enhance cooling efficiency.
Implementation Method 1
The working fluid is sent through the inside of the tubes and the heat is conducted to the outside of the tubes and the fins
Implementation Method 2
Air passing over the fins and tubes removes this heat
Implementation Method 3
Optional adiabatic pads or adiabatic pre-cooling spray nozzles may be provided to pre-cool the air entering the system
Data Source
AI summary
A modular double V stacked dry or adiabatic heat exchanger having a bottom module with two heat exchangers arranged in a V-shape, a top module configured to rest atop and be supported by the bottom module and having two heat exchangers configured to continue and extend the V-shape formed by the two bottom heat exchangers, and a fan module configured to rest atop and be supported by the top module. The modules are factory assembled and configured to for easy shipping and connection to one-another on-site. Adiabatic pads or spray nozzles may be provided to pre-cool the air entering the system.