Heat exchanger and method for manufacturing such a heat exchanger
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Solution Overview
Problem
Heat exchangers used in refrigeration dryers face challenges in achieving uniform distribution of a two-phase fluid flow, leading to inefficient heat exchange, pressure drops, and potential freezing, due to uneven distribution and phase separation, especially under varying load conditions.
Innovation Solution
A heat exchanger design featuring a single-body flow-rate distribution means with inclined flow-conducting surfaces and a compact inlet collector structure ensures even distribution of the two-phase fluid across channels, maintaining velocity and preventing phase separation, while a cuboid outlet collector promotes uniform outflow and pressure equalization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional inlet collectors are used without flow-rate distribution means, then the structure is simple, but the two-phase fluid flow is unevenly distributed across channels leading to inefficient heat exchange and pressure drops
Solution Approach 1:
The inlet collector is segmented into multiple functional zones using flow-rate distribution means, including inclined flow-conducting surfaces that divide the inlet collector chamber into regions. This segmentation ensures uniform distribution of two-phase fluid flow across different channel groups, optimizing heat exchange efficiency while maintaining a manageable structural complexity through systematic zoning.
Solution Approach 2:
Different regions of the inlet collector are given different local qualities through inclined flow-conducting surfaces with specific angles. These surfaces create zones with varying flow characteristics, directing two-phase fluid flow appropriately to different channel groups. This local differentiation ensures uniform flow distribution without requiring complete redesign of the entire inlet collector structure.
2Stability of the object's composition
If the inlet collector chamber volume is increased to allow two-phase fluid flow, then phase separation is reduced, but the velocity of the fluid decreases leading to increased pressure drops
Solution Approach 1:
The inlet collector design incorporates dynamic flow control through inclined flow-conducting surfaces that actively guide two-phase fluid flow. These surfaces create a balanced flow regime that maintains sufficient fluid velocity to prevent phase separation while directing flow uniformly across channels. The dynamic interaction between the inclined surfaces and fluid flow optimizes both phase stability and pressure characteristics.
Solution Approach 2:
The inclined flow-conducting surfaces introduce a dimensional element by creating inclined planes within the inlet collector chamber. This three-dimensional flow guidance structure distributes two-phase fluid flow across multiple spatial dimensions, ensuring uniform velocity distribution and preventing phase separation without requiring excessive chamber volume that would reduce overall flow velocity.
3Manufacturing precision
If flow-rate distribution means are added to the inlet collector, then uniform fluid distribution is achieved, but manufacturing complexity increases
Solution Approach 1:
The flow-rate distribution means are merged with the inlet collector structure itself, forming an integrated component. The inclined flow-conducting surfaces are incorporated directly into the inlet collector housing, eliminating the need for separate distribution devices. This merging approach achieves uniform fluid distribution while simplifying manufacturing by reducing the number of parts and assembly steps.
Solution Approach 2:
The inlet collector is designed with multi-functionality, serving both as the structural housing and as the flow-rate distribution mechanism. The inclined flow-conducting surfaces perform dual functions: maintaining structural integrity and distributing two-phase fluid flow uniformly. This universal design approach reduces manufacturing complexity by combining multiple functions into a single component.
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
This design enhances heat exchange efficiency by maintaining uniform fluid distribution, reducing pressure drops, and preventing freezing, even under lower load conditions, thereby improving the overall performance and stability of the refrigeration dryer.
Implementation Method 1
a particularly efficient heat exchange between the compressed air and the cooling agent is achieved when the cooling agent in the channels is subject to an evaporation process during the heat exchange. After all, during this evaporation process the cooling agent absorbs heat from the compressed air, while the temperature of the cooling agent remains constant and does not rise
Implementation Method 2
the cooling agent is typically presented to the channels of the heat exchanger as a two-phase fluid flow of gas or vapour on the one hand and liquid on the other hand
Implementation Method 3
heat exchanger for exchanging heat between two fluids, respectively a first initially two-phase fluid and a second fluid
Data Source
Figure 1
Figure 2
Figure 3a
AI summary
A heat exchanger with - a housing (3) that contains a set of channels (12); - an inlet collector (4) having an inlet collector chamber (9) with an inlet (5), wherein both inlet (5) and inlet collector chamber (9) are symmetrical according to a first plane of symmetry and a second plane of symmetry intersecting said first plane of symmetry, and wherein the inlet collector chamber (9) includes first flow distribution means (10) configured to distribute a flow originating from the inlet (5) evenly over the set of channels (12); and - an outlet collector (6), characterized in that the first flow-rate distribution means (10) consist of a single body (15) that comprises two flow-conducting surfaces (16), which two flow-conducting surfaces (16) are symmetrical with respect to each other according to the first plane of symmetry and the second plane of symmetry, and which two flow-conducting surfaces (16), as seen from the inlet (5), are inclined downward in a first direction perpendicular to the first plane of symmetry and/or in a second direction perpendicular to the second plane of symmetry.