Flat Heat-Exchange Tube Geometry to Prevent Gas Bypass
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Solution Overview
Problem
Existing heat exchanger tubes in EGR systems face issues with gas bypass through larger lateral channels, leading to reduced efficiency and fouling due to lower gas speed, which is not adequately addressed by additional pieces that complicate manufacturing.
Innovation Solution
A flat tube configuration with internal fins and deformed portions in the curved wall segments to reduce the hydraulic diameter of lateral channels, enhancing gas flow through the fins and preventing bypass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the lateral channels have a larger hydraulic diameter to facilitate gas flow, then the gas flow resistance is reduced, but the gas bypasses the fins reducing heat exchange efficiency and causing fouling
Solution Approach 1:
The curved wall segment is deformed locally at specific positions to reduce the passage section of lateral channels, creating different flow resistance characteristics in different regions of the tube. This local modification ensures that gas flow is properly directed through the fins while maintaining adequate flow speed
Solution Approach 2:
The hydraulic diameter of the lateral channels is modified by deforming the curved wall segment, changing the geometric parameters of the channel to adjust flow resistance and gas distribution between lateral channels and fin channels
2Reliability
If additional pieces are added to prevent bypass in lateral channels, then heat exchange efficiency is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The function of guiding gas flow through the fins is integrated into the curved wall segment itself through localized deformation, eliminating the need for separate additional pieces or components. The tube structure performs multiple functions including heat exchange and flow guidance
Solution Approach 2:
The curved wall segment deforms itself to create the necessary flow resistance in the lateral channels, using its own structure to prevent bypass rather than requiring external components to enforce flow direction
3Reliability
If additional pieces are added to prevent bypass in lateral channels, then heat exchange efficiency is improved, but manufacturing cost and process complexity increase
Solution Approach 1:
The flow control function is merged into the tube manufacturing process itself through deformation of the curved wall segment, allowing the feature to be created during or after tube formation without requiring separate assembly steps for additional components
Solution Approach 2:
The tube structure self-regulates gas flow through its own deformed geometry, eliminating the need for additional manufacturing steps to install separate flow control components
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
Enhances heat transfer efficiency by increasing gas speed through internal channels, reducing fouling, and maintaining structural integrity without additional manufacturing steps.
Implementation Method 1
the hydraulic diameter of the lateral channels is larger than the hydraulic diameter of the internal channels, wherein at least one curved wall segment comprises a deformed portion, with a configuration of the deformed portion penetrating into the lateral channel reducing the section thereof
Implementation Method 2
The hot gas gives off its heat to the fins, which in turn transfer said heat to the flat walls of the tube
Implementation Method 3
The hot gas gives off its heat to the fins, which in turn transfer said heat to the flat walls of the tube
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
The present invention relates to a device for heat exchange between a hot gas and a liquid coolant. The tube has a flat configuration, with intermediate channels formed by a set of fins and two lateral channels with a larger hydraulic diameter. The invention is characterized by a specific way of reducing the passage section in order to prevent a by-pass effect in the tube so that gas flow is directed mainly through the set of fins.