Filter Unit Heat Exchanger With Offset Airflow Paths
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Solution Overview
Problem
Commercial kitchens face inefficiencies in heat energy recovery due to the placement of heat exchangers downstream of grease filters, leading to thermal energy loss and increased costs, as well as the need for frequent cleaning of filters to prevent fouling and safety hazards.
Innovation Solution
A combined system with a filter unit that includes a heat exchanger positioned closer to the heat source, utilizing a housing with entrance and exit apertures and baffles to redirect airflow for increased heat transfer efficiency, and a heat-conductive material coated with a reduced friction material like polytetrafluoroethylene to enhance airflow and reduce maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If heat exchanger is positioned downstream of grease filter, then heat transfer efficiency is reduced due to distance from heat source, but grease filtration is still achieved
Solution Approach 1:
The patent combines the heat exchanger and grease filter into a single integrated unit, with the heat exchanger positioned upstream of the grease filter. This merging eliminates the need for separate components and allows direct heat recovery from the exhaust stream before grease accumulation, resolving the contradiction between energy loss and heat transfer efficiency.
Solution Approach 2:
The patent inverts the conventional arrangement by placing the heat exchanger upstream of the grease filter rather than downstream. This inversion allows the heat exchanger to capture thermal energy directly from the hot exhaust gases before they contact the filter media, maximizing heat transfer efficiency while still achieving effective grease filtration.
2Object-generated harmful factors
If grease filter is placed upstream of heat exchanger, then grease filtration is achieved, but air flow is significantly impeded when congested with grease
Solution Approach 1:
The patent inverts the conventional arrangement by placing the heat exchanger upstream of the grease filter. This inversion allows the heat exchanger to capture thermal energy directly from the hot exhaust gases before they contact the filter media, maximizing heat transfer efficiency while still achieving effective grease filtration.
Solution Approach 2:
The patent segments the exhaust treatment process into two distinct stages: first heat recovery through the heat exchanger, then grease filtration through the filter media. This segmentation allows each component to perform its function optimally without interfering with the other, maintaining air flow efficiency while achieving effective grease removal.
3Ease of manufacture
If heat exchanger is located downstream of grease filter, then integration with existing systems is simpler, but valuable thermal energy is lost through absorption into filter and dissipation
Solution Approach 1:
The patent combines the heat exchanger and grease filter into a single integrated unit, with the heat exchanger positioned upstream of the grease filter. This merging eliminates the need for separate components and allows direct heat recovery from the exhaust stream before grease accumulation, resolving the contradiction between energy loss and heat transfer efficiency.
4Power
If grease filter includes heat exchange fins, then heat transfer capability is enhanced, but grease solidifies on fins when heat source is off requiring frequent cleaning
Solution Approach 1:
The patent inverts the conventional arrangement by placing the heat exchanger upstream of the grease filter. This prevents grease-laden air from contacting the heat exchange fins, eliminating grease accumulation on the fins while maintaining heat transfer capability through the upstream positioned heat exchanger.
Solution Approach 2:
The patent introduces an intermediary arrangement where the heat exchanger is positioned upstream of the grease filter, creating a protective barrier that prevents grease from contacting the heat exchange fins. This intermediary positioning maintains heat transfer capability while preventing grease accumulation that would require frequent cleaning.
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 effectively recovers heat energy from kitchen exhausts, reducing energy losses and maintenance costs by integrating a heat exchanger within the filter unit, allowing for more efficient heat transfer and prolonged filter life.
Implementation Method 1
a heat exchanger disposed substantially within the cavity... when a gas is drawn through the at least one entrance aperture and across the heat exchanger
Implementation Method 2
hot fumes and/or air being vented to the atmosphere... heat transfer efficiency
Implementation Method 3
a heat-conductive material coated with a reduced friction material like polytetrafluoroethylene to enhance airflow
Data Source
AI summary
An embodiment of filter unit heat exchanger according to the present invention provides improved operability and manufacturability. Such device may include a housing substantially surrounding a heat exchange assembly. Provided through the housing are one or more tortuous fluid flow paths used to direct airflow therethrough around portions of the heat exchange assembly for efficient operation. The tortuous path(s) may be provided by one or more nozzle apertures on an input side of the housing and one or more diffuser apertures on an output side of the housing, where the nozzle apertures and diffuser apertures are offset to cause desired airflow deflection. The filter unit may include desired symmetries so as to improve manufacturability and/or installation.