Flat-Flange Aluminium Condenser Tube for Lower Pressure Drop
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing condenser tubes for heat transfer in domestic water heating systems are inefficient due to poor heat conductivity in steel and stainless steel tanks, requiring long tubes with large crossflow areas, which increases pressure drop and reduces energy efficiency.
Innovation Solution
A condenser tube profile with a substantially flat flange integrated at its periphery, made of aluminium or an aluminium alloy, is wound in a helix shape around the tank, providing enhanced thermal contact and efficient heat transfer with a reduced tube length and cross-sectional flow area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If round, flattened round or D-shaped aluminium condenser tubes are wrapped around the tank, then heat transfer to the liquid in the tank is achieved, but the tube length becomes very long (50-60 meters) due to poor heat conductivity in steel and stainless steel
Solution Approach 1:
The invention transitions from point-contact heat transfer (round tubes) to surface-contact heat transfer by introducing a flat flange that contacts the tank surface. This dimensional change from linear contact to areal contact dramatically improves heat transfer efficiency, reducing the required tube length from 50-60 meters to a much shorter length while maintaining the same heat transfer effectiveness.
Solution Approach 2:
The flat flange acts as an intermediary element between the condenser tube and the tank surface. It improves thermal contact by distributing the heat transfer over a larger contact area, effectively bridging the thermal resistance gap caused by poor heat conductivity in steel and stainless steel tanks.
2Reliability
If the condenser tubes are wrapped close to each other and over a greater part of the tank to compensate for poor heat conductivity, then enough heating energy is transferred to the liquid, but the crossflow area becomes large resulting in high pressure drop
Solution Approach 1:
By introducing the flat flange that contacts the tank surface, the heat transfer mechanism shifts from relying on tube-to-tube proximity to relying on tube-to-surface contact area. This allows the system to achieve sufficient heating energy transfer with reduced tube density, thereby reducing the crossflow area and pressure drop in the refrigeration cycle.
3Use of energy by moving object
If large crossflow area is used to reduce pressure drop, then energy efficiency is maintained, but refrigerant charge increases which conflicts with GWP restrictions and safety requirements
Solution Approach 1:
The flat flange introduces a new dimension of heat transfer through surface contact, which improves heat transfer efficiency per unit length of tube. This allows the system to maintain energy efficiency (COP) with reduced refrigerant charge, as the improved thermal contact compensates for the shorter tube length and smaller crossflow area.
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 achieves a significant reduction in tube length and refrigerant charge while maintaining or improving energy efficiency, allowing for the use of low GWP hydrocarbon refrigerants and reducing material usage.
Implementation Method 1
the flange is arranged in thermal contact with the outer surface of the said object
Implementation Method 2
heat transfer between a medium transported inside at least one channel of said condenser tube profile and a medium, preferably a liquid, contained in said object
Implementation Method 3
the condenser tube profile is winded onto the outer surface of the said object, wherein the condenser tube profile has a substantially flat flange with a flange width (FW) integrated in parallel with a longitudinal direction of the condenser tube
Data Source
AI summary
A condenser tube profile, a method and an apparatus for heat exchange where a condenser tube profile is applied for heat exchange purposes. The condenser tube profile is made of aluminium or an aluminium alloy in an extrusion process, and a heat transfer medium is transported through one or more channels arranged in the said tube profile. A substantial flat flange is integrated with the tube profile. The tube profile can be winded in a shape of a helix onto the outer surface of an object, and where the flat flange is arranged firmly onto the surface of the object. Also, a method for heat transfer between a heat transfer medium flowing through such condenser tube and a liquid in a tank as well as an apparatus such as a domestic water heater of steel or stainless steel provided with said heat transfer arrangement.