Heat Exchanger Blocking Element Gas Flow Redirection
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Solution Overview
Problem
Existing gas-liquid heat exchangers face inefficiencies in cooling hot gases due to gas bypass flow and suboptimal heat exchange between hot gases and liquid coolants, particularly at the top and bottom gas flow passages which have higher outlet temperatures and reduced cooling capacity.
Innovation Solution
The design incorporates a heat exchanger core with a blocking element along the front or rear face to divert gas flow from the uppermost and lowermost gas flow passages to intermediate passages, enhancing heat transfer and using turbulence-enhancing inserts and core plates with bosses to define coolant manifolds and improve sealing between manifold covers and the core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If gas flow passages are provided at the top and bottom of the core, then space is saved and cost is reduced, but outlet temperatures are higher and cooling efficiency is reduced
Solution Approach 1:
The patent applies local quality by providing blocking elements specifically at the top and bottom gas flow passages to redirect gas flow locally to intermediate passages, while maintaining the overall compact structure. This creates different flow characteristics in different regions of the heat exchanger core.
Solution Approach 2:
The gas flow passages are segmented into different zones (top/bottom vs. intermediate) with different flow characteristics. The blocking elements create distinct flow paths that segment the gas flow to optimize cooling in specific regions while maintaining compact dimensions.
2Loss of energy
If turbulence-enhancing inserts are added to gas flow passages, then heat transfer is improved, but device complexity increases
Solution Approach 1:
The patent changes the geometric parameters of the gas flow passages by incorporating turbulence-enhancing inserts with specific shapes and configurations. These inserts modify flow parameters (turbulence intensity, velocity distribution) to enhance heat transfer without requiring fundamental redesign of the heat exchanger structure.
3Quantity of substance
If manifold covers are connected directly to the core, then material costs and weight are reduced, but sealing difficulty increases
Solution Approach 1:
The patent introduces sealing elements as intermediary components between the manifold covers and the core. These sealing elements act as mediators that enable reliable sealing while maintaining the self-enclosed structure, resolving the conflict between material reduction and sealing reliability.
4Productivity
If blocking elements are added to redirect gas flow, then cooling efficiency is improved, but device complexity increases
Solution Approach 1:
The blocking elements are merged with the existing core structure or manifold covers, combining the flow redirection function with the structural components already present in the heat exchanger. This integration minimizes additional complexity while achieving improved cooling efficiency.
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 configuration improves cooling efficiency by redirecting gas flow to increase heat exchange with intermediate passages, minimizing gas bypass and optimizing heat transfer, thus enhancing the overall performance of the heat exchanger.
Implementation Method 1
a blocking element extending along either the front face or the rear face of the core and at least partly blocking the endmost gas flow passage
Implementation Method 2
each of the flat tubes enclosing a liquid flow passage for circulation of a liquid coolant; a plurality of gas flow passages, each of which is defined in a space between an adjacent pair of said flat tubes
Implementation Method 3
the gas flow passages are provided with turbulence-enhancing inserts to improve heat transfer from the hot gas to a liquid coolant
Data Source
AI summary
A gas-liquid heat exchanger such as a charge air cooler has a core comprising a stack of flat tubes defining liquid coolant flow passages, and a plurality of open-ended gas flow passages between the flat tubes. An endmost gas flow passage is defined between an end plate of the core and an adjacent flat tube, such that the endmost gas flow passage is in contact with only said adjacent one of said flat tubes. A blocking element extends along either the front face or the rear face of the core and at least partly blocking the endmost gas flow passage. Each flat tube may comprise a pair of core plates, at least one including a flap projecting into a gas flow passage and covering a gas bypass channel between the edge of the turbulence-enhancing insert and the sides of a coolant manifold.