Heat Exchanger with Alternating Flow Sections
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Solution Overview
Problem
Existing heat exchangers face challenges with increased pressure drops and size/weight due to multiple flow sections, which affect efficiency and require more power to maintain fluid flow.
Innovation Solution
A heat exchanger design with a core that divides fluid circuits into alternating flow sections with opposing fluid directions, reducing the number of flow passages and using bypass channels to split and recombine coolant flow, thereby minimizing pressure drops and maintaining efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If heat exchangers are divided into multiple flow sections to increase heat exchange efficiency, then heat exchange efficiency is improved, but pressure drops of working fluids increase and size/weight increase
Solution Approach 1:
The first fluid circuit is divided into two sub-circuits (first sub-circuit and second sub-circuit) that are connected in parallel between the inlet and outlet. This segmentation allows the fluid flow to be split into multiple paths, reducing the flow velocity and pressure drop in each individual path while maintaining overall heat exchange efficiency through the alternating flow sections configuration.
Solution Approach 2:
The patent employs an alternating flow sections configuration where flow sections of the first fluid circuit and second fluid circuit alternate in sequence. This spatial arrangement creates counter-current heat exchange zones that enhance heat transfer efficiency without requiring additional flow sections, thereby avoiding increased pressure drops and dimensions.
2Productivity
If heat exchangers are divided into multiple flow sections to increase heat exchange efficiency, then heat exchange efficiency is improved, but size and weight of heat exchanger increase
Solution Approach 1:
The first sub-circuit and second sub-circuit are merged into a single integrated core structure with alternating flow sections. This merging allows both sub-circuits to share the same physical space and heat exchange surfaces, achieving high heat exchange efficiency without proportionally increasing the overall size and weight of the heat exchanger.
Solution Approach 2:
The alternating flow sections configuration effectively nests the first and second fluid circuits within each other in a compact arrangement. The flow sections alternate spatially, allowing maximum heat exchange surface area within a minimized volume, thereby reducing size and weight while maintaining efficiency.
3Volume of stationary object
If number of flow passages is reduced to decrease size, then size is reduced, but heat exchange efficiency may decrease
Solution Approach 1:
The alternating flow sections configuration creates localized counter-current heat exchange zones throughout the core. Each alternating section provides intensive local heat transfer, ensuring that even with a reduced total number of flow passages, the overall heat exchange efficiency is maintained through enhanced local heat transfer coefficients in the counter-current zones.
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 design reduces the size and weight of the heat exchanger while maintaining heat exchange efficiency, lowering pressure drops and energy consumption, achieving a good balance between power and size, and reducing costs associated with fluid flow equipment.
Implementation Method 1
a wall separating the first and second fluid circuits from each other
Implementation Method 2
a direction of the first flow of the first fluid through the first flow section of the first fluid circuit is opposite to a direction of flow of a second fluid through the second flow section of the second fluid circuit
Data Source
Figure 1~2
Figure 3a~3b
Figure 4~5
AI summary
A heat exchanger (1) comprises a core (2), which defines first and second fluid circuits therein. Both fluid circuits are divided into two flow sections (21C, 22C and 21R, 22R). The first fluid circuit is split into first and second sub-circuits. A direction of a first flow of a first fluid through the first flow section (21C) of the first fluid circuit is opposite to a direction of flow of a second fluid through the second flow section (22R) of the second fluid circuit and a direction of a second flow of the first fluid through the second flow section (22C) of the first fluid circuit is opposite to the direction of flow of the second fluid through the first flow section (21R) of the second fluid circuit.