Flow Adapter Sealing in Pressure Exchangers for Compact Pressure Boosting
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Solution Overview
Problem
Conventional systems for increasing fluid pressure in applications like refrigeration and heat pump systems are inefficient, requiring large amounts of energy and material, and have components that are bulky and time-consuming to produce.
Innovation Solution
The use of pressure exchangers (PXs) that exchange pressure between fluids, reducing energy consumption and wear on components, and eliminating the need for bore machining by using flow adapters to seal and distribute pressure efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional pumps or compressors are used to increase fluid pressure, then pressure increase function is achieved, but energy consumption is large
Solution Approach 1:
The patent combines the compression function and expansion function into a single integrated pressure exchanger device. The high-pressure fluid stream directly drives the compression of the low-pressure fluid stream through hydraulic coupling, merging what would traditionally require separate compressor and expansion valve components into one unit that recovers and utilizes pressure energy internally.
Solution Approach 2:
The pressure exchanger uses a hydraulic intermediary mechanism where the high-pressure fluid acts as a driving medium to compress the low-pressure fluid without direct mechanical contact. This intermediary hydraulic coupling allows energy transfer between fluid streams while minimizing losses associated with traditional mechanical compressors.
2Power
If conventional pumps or compressors are used to increase fluid pressure, then pressure increase function is achieved, but component size is bulky
Solution Approach 1:
The patent combines the compression function and expansion function into a single integrated pressure exchanger device. The high-pressure fluid stream directly drives the compression of the low-pressure fluid stream through hydraulic coupling, merging what would traditionally require separate compressor and expansion valve components into one unit that recovers and utilizes pressure energy internally.
Solution Approach 2:
The pressure exchanger utilizes hydraulic principles to transfer energy between fluid streams. By using hydraulic pressure directly to drive the compression process rather than mechanical rotating equipment, the system achieves compact dimensions while maintaining effective pressure increase capability.
3Ease of manufacture
If conventional pumps or compressors are used to increase fluid pressure, then pressure increase function is achieved, but production time is time-consuming
Solution Approach 1:
The pressure exchanger is designed as a modular assembly of discrete components including the housing, rotor with channels, end covers with ports, and flow adapters. This segmentation allows each component to be manufactured separately using optimized processes and then assembled, reducing overall production time and enabling parallel manufacturing of components.
Solution Approach 2:
The rotor component serves multiple functions simultaneously: it contains the fluid channels for pressure exchange, provides the structural framework for the device, and creates the hydraulic coupling between high-pressure and low-pressure streams. This multi-functionality reduces the total number of parts needed and simplifies the manufacturing process.
4Use of energy by moving object
If pressure exchangers with flow adapters are used, then energy consumption is reduced, but device complexity increases
Solution Approach 1:
The flow adapter is designed to perform multiple functions: it seals the interface between the rotor and end cover, distributes fluid flow to appropriate ports, and maintains hydraulic pressure boundaries. This multi-functionality consolidates what would otherwise require multiple separate components, reducing overall device complexity while maintaining energy efficiency.
Solution Approach 2:
The flow adapter acts as an intermediary component that simplifies the interface between the rotating rotor and stationary end covers. It provides a standardized sealing and flow distribution mechanism that reduces the complexity of achieving reliable pressure boundaries and fluid distribution in the pressure exchanger.
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
PXs reduce energy consumption, minimize material waste, and decrease production time while offering more applications compared to conventional systems.
Implementation Method 1
The PX is configured to exchange pressure between a first fluid and a second fluid
Data Source
AI summary
A pressure exchanger includes a rotor, an end cover, and a flow adapter. The rotor is configured to exchange pressure between fluids. The end cover is disposed at a distal end of the rotor. The end cover forms end cover low pressure ports and end cover high pressure ports. The flow adapter includes a planar surface, a distal end, and a upper surface. The planar surface forms planar low pressure openings and planar high pressure openings and is configured to seal to the end cover. The distal end forms a distal low pressure opening. Low pressure fluid flow is between the end cover low pressure ports and the distal low pressure opening via the planar low pressure openings. The upper surface forms upper high pressure openings. High pressure fluid flow is between the end cover high pressure ports and the upper high pressure openings via the planar high pressure openings.