Flow Funneling Insert for Heat Exchanger Pressure Drop Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Heat exchangers experience significant pressure drops due to abrupt transitions from large inlet and outlet reservoirs to tubes, which impede the efficient flow of cooling fluids.
Innovation Solution
The introduction of flow funneling inserts with guide members that expand from a narrow aperture near the tubes to a wider aperture near the tanks, facilitating smoother fluid flow and reducing pressure drops by guiding the fluid through a series of funnels within the heat exchanger.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If tubes extend freely into inlet and outlet reservoirs or terminate abruptly at an end plate, then the structure is simple, but large pressure drops occur across the heat exchanger
Solution Approach 1:
Flow distribution members are introduced as intermediary components between the inlet/outlet reservoirs and the tubes. These members act as mediators that gradually transition the fluid from the large reservoir volume to the smaller tube cross-section, reducing abrupt pressure drops while maintaining structural simplicity.
Solution Approach 2:
The flow distribution members are configured with curved or tapered surfaces that gradually guide the fluid flow from the reservoir into the tubes. This curved geometry eliminates sharp transitions and reduces flow separation, thereby minimizing pressure drops without significantly increasing structural complexity.
2Ease of manufacture
If abrupt transitions are used from reservoirs to tubes, then manufacturing is easier, but fluid flow efficiency deteriorates
Solution Approach 1:
The flow distribution system is segmented into multiple flow distribution members, each responsible for directing flow to specific tubes or groups of tubes. This segmentation allows each member to have a simpler, more manufacturable geometry while collectively achieving efficient flow distribution across all tubes.
Solution Approach 2:
The flow distribution members are designed with varying geometric parameters (such as taper angles, lengths, and positions) optimized for manufacturing. By carefully selecting these parameters, the components can be easily manufactured using standard processes while still achieving gradual flow transitions that maintain high fluid flow efficiency.
Data Source
AI summary
A heat exchanger can include a core, a first tank, and a set of guide members. The core can include a first end member, a second end member, and a plurality of tubes that can extend longitudinally between the first and second end members. The first tank can be fixedly coupled to the first end member. The first tank and first end member can define a first chamber that can be in fluid communication with a first port of the first tank and a first end of the tubes. The set of guide members can be coupled to the first end member. The set of guide members can cooperate to define a plurality of first funnels. A narrow end of each first funnel can be open to an individual one of the tubes. A wide end of each first funnel can be open to the first chamber.