Dual-Circuit Heat Exchanger Header Layout for Lower Pressure Loss
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Solution Overview
Problem
Heat exchangers in motor vehicle air conditioning systems face pressure loss issues when not in use, leading to diminished performance and increased costs due to the need for bypassing components, which affects the coefficient of performance.
Innovation Solution
A heat exchanger design featuring separate circuits with additional headers and chambers formed by stacked plates, allowing for efficient fluid flow and heat exchange, reducing pressure loss and simplifying assembly and installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the refrigerant fluid is circulated through the heat exchanger without the heat-transfer liquid when air conditioning is not in use, then the system structure is simpler and cost is reduced, but pressure loss increases and coefficient of performance worsens
Solution Approach 1:
The heat exchanger is divided into multiple independent circuits (first circuit for refrigerant, second circuit for heat-transfer liquid) with separate inlet and outlet headers. This segmentation allows each circuit to be optimized independently, enabling the refrigerant to flow through dedicated passages without requiring the heat-transfer liquid circuit to be active, thereby reducing pressure loss while maintaining system simplicity.
Solution Approach 2:
The patent introduces a multi-circuit architecture with separate refrigerant and heat-transfer liquid circuits as intermediary pathways. This allows the refrigerant to bypass the heat-transfer liquid circulation requirement while still achieving effective heat exchange through the dedicated first circuit, resolving the conflict between system simplicity and performance.
2Power
If traditional multi-pass heat exchanger design is used, then thermal performance is improved, but pressure loss increases and device complexity increases
Solution Approach 1:
The heat exchanger employs multiple independent circuits (first circuit for refrigerant, second circuit for heat-transfer liquid) with separate inlet and outlet headers for each circuit. This segmentation allows thermal performance to be optimized in each circuit independently while avoiding the complexity of traditional multi-pass designs that require intricate internal flow paths.
Solution Approach 2:
The patent transitions from a traditional single-circuit multi-pass design to a multi-circuit parallel architecture, adding the dimension of circuit independence. This allows heat exchange to occur through multiple simultaneous pathways rather than sequential passes, reducing pressure loss and simplifying the overall device structure while maintaining or improving thermal performance.
3Power
If traditional multi-pass heat exchanger design is used, then thermal performance is improved, but pressure loss increases
Solution Approach 1:
The heat exchanger is segmented into multiple independent circuits with separate inlet and outlet headers, allowing the refrigerant to flow through dedicated passages without the pressure losses associated with traditional multi-pass designs. Each circuit can be optimized for minimal pressure drop while maintaining effective heat exchange.
Solution Approach 2:
By introducing multiple independent circuits as an additional dimensional approach, the patent enables parallel heat exchange pathways that reduce pressure loss compared to sequential multi-pass designs. The separate circuits allow for more direct flow paths while achieving the required thermal performance.
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 design enhances heat exchange coefficients and reduces pressure loss, improving system performance and reducing costs by allowing for efficient fluid circulation and heat transfer, even when the vehicle air conditioning is not in use.
Implementation Method 1
heat exchanger for a motor vehicle, comprising: a first circuit intended to be traversed by a heat-transfer fluid, comprising a first inlet header through which the heat-transfer fluid is admitted into the first circuit and a first outlet header through which the heat-transfer fluid leaves the first circuit
Implementation Method 2
a counter-current flow is used in the first and third passes, where the refrigerant is mainly single-phase, and a co-current flow is used where the refrigerant is mainly two-phase to obtain a good exchange coefficient
Data Source
AI summary
A heat exchanger for a motor vehicle is disclosed. The heat exchanger includes a first circuit configured to be traversed by a heat-transfer fluid. The first circuit includes a fires inlet header through which the heat-transfer fluid is admitted into the first circuit, and a first outlet header through which the heat-transfer fluid leaves the first circuit. The heat exchanger also includes a second circuit configured to be traversed by a heat-transfer fluid. The second circuit is fluidically separate from the first circuit and includes a second inlet header and a second outlet header. The heat-transfer fluid is admitted into the heat exchanger through the second inlet header and leaves through the second outlet header. The first circuit or second circuit includes an additional header that extends in the same direction as the inlet headers and outlet headers of the first circuit and the second circuit.