Evaporator Cuff Serpentine Flow for Freezing Large-Diameter Pipes
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Solution Overview
Problem
Conventional portable pipe freezer systems are unable to effectively freeze large diameter pipes due to insufficient heat removal capabilities, requiring costly and complex two-stage cooling systems or the use of substances like liquid nitrogen, compressed air, or CO2 to achieve the necessary low temperatures for creating an ice plug.
Innovation Solution
A portable pipe freezer system featuring an evaporator cuff with a serpentine flow path and baffles to enhance refrigerant flow, combined with a flow distributor to minimize temperature differentials between evaporator cuffs, allowing for the production of temperatures as low as −70 degrees F using conventional refrigerants, effectively freezing large diameter pipes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional portable condensers are used to cool large diameter pipes, then the system is simple and cost-effective, but the temperature cannot reach −55 degrees F. required for freezing
Solution Approach 1:
The evaporator is divided into multiple sections with internal baffles that create separate flow paths. This segmentation increases the surface area for heat exchange and improves refrigerant distribution, enabling conventional condensers to achieve the required −55 degrees F. temperature for freezing large diameter pipes without requiring complex two-stage cooling systems.
Solution Approach 2:
The invention introduces internal baffles and serpentine flow paths within the evaporator chamber, transforming the refrigerant flow from a simple linear path to a multi-dimensional serpentine pattern. This increases the effective heat exchange surface area and improves temperature distribution, allowing conventional portable condensers to achieve the required freezing temperatures.
2Temperature
If two-stage cooling systems are used to achieve −55 degrees F., then the freezing capability is sufficient, but the system cost and complexity increase significantly
Solution Approach 1:
The evaporator chamber is segmented into multiple flow paths using internal baffles, creating a serpentine refrigerant flow pattern. This segmentation increases heat exchange efficiency and surface area utilization, enabling a single-stage cooling system to achieve the −55 degrees F. temperature that would otherwise require complex two-stage systems.
Solution Approach 2:
The serpentine flow path created by the baffles ensures continuous and uniform refrigerant flow through the entire evaporator chamber, maximizing heat exchange efficiency throughout the entire surface area. This continuous useful action allows a single-stage system to achieve the required cooling temperatures.
3Temperature
If liquid nitrogen, compressed air with vortex tubes, or CO2 are used, then the required low temperatures can be achieved, but the systems are difficult to use and costly
Solution Approach 1:
The evaporator design with internal baffles and serpentine flow paths enables the conventional refrigeration system to self-regulate and achieve the required −55 degrees F. temperature through optimized refrigerant distribution and heat exchange, eliminating the need for specialized cooling agents like liquid nitrogen or complex vortex tube systems.
Solution Approach 2:
The invention changes the physical parameters of the evaporator system by introducing baffles and serpentine flow paths, which optimize heat transfer coefficients and refrigerant flow characteristics. These parameter changes enable conventional refrigerants to achieve the required low temperatures with standard portable condensers, improving ease of operation.
4Productivity
If standard evaporator heads are used for large diameter pipes, then the system design is simple, but the heat removal capability is insufficient to freeze the liquid
Solution Approach 1:
The evaporator is segmented into multiple flow paths using internal baffles, increasing the effective heat exchange surface area and improving refrigerant distribution across the entire evaporator surface. This segmentation enhances heat removal capability from the pipe, enabling freezing of large diameter pipes that would otherwise require overly complex systems.
Solution Approach 2:
The serpentine flow path introduced by the baffles transforms the refrigerant flow from a simple linear pattern to a multi-dimensional serpentine pattern that maximizes contact with the evaporator surface. This dimensional change increases heat exchange efficiency and heat removal capability without requiring excessive system complexity.
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 system efficiently freezes large diameter pipes by achieving the required low temperatures, reducing temperature differentials, and minimizing costs associated with complex cooling systems, thereby ensuring consistent ice plug formation without the need for expensive cooling agents.
Implementation Method 1
The refrigerant causes the evaporator heads to freeze the pipe where they are in contact
Implementation Method 2
By freezing the fluid in the pipe, it is possible to block the fluid in the section of pipe of interest by creating an ice plug
Data Source
AI summary
An evaporator cuff for use with a pipe freezer apparatus. The evaporator cuff includes a hose connector attached to an evaporator body. The evaporator body has an inner wall configured to engage the outer surface of a pipe, an outer wall spaced apart from the inner wall. A chamber is defined between the inner and outer walls, first and second side walls, and first and second end walls. A plurality of baffles are located in the chamber and arranged to define a series of conduits for creating a flow path through the chamber for refrigerant to flow along. The walls are arranged so as to form a serpentine flow path from the evaporator inlet to the evaporator outlet.