Heat Exchanger Bypass Control and Structural Reinforcement
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Solution Overview
Problem
Conventional water-cooled intercoolers experience reduced heat exchange efficiency and increased pressure loss due to air bypassing the heat exchanger core, and have low mechanical strength, leading to deformation under high-pressure air flow.
Innovation Solution
A heat exchanger design that includes a core portion with inlet and outlet header tanks, tubes, and fins, along with a side reinforcing plate and blocking plate to minimize bypass areas and enhance structural rigidity, reducing pressure loss and preventing air leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the water-cooled intercooler is surrounded with a case to prevent air bypass, then heat exchange efficiency is improved, but pressure loss increases due to air not passing through the core
Solution Approach 1:
The case is divided into a first case and a second case with a bypass passage connecting them. The blocking member segments the air flow path, forcing air to pass through the core portion rather than bypassing it entirely. This segmentation allows the system to maintain heat exchange efficiency while reducing pressure loss by providing a controlled flow path through the core.
Solution Approach 2:
A blocking member is introduced as an intermediary element within the bypass passage. This blocking member prevents air from taking the捷径 through the bypass, thereby ensuring air flows through the heat exchanger core. The blocking member acts as a mediator that reconciles the conflicting requirements of maintaining efficiency and reducing pressure loss.
2Strength
If a top plate is joined to the heat exchanger core for strength reinforcement, then mechanical strength is improved, but air leakage occurs due to deformation under high-pressure air flow
Solution Approach 1:
The reinforcing plate and blocking member are merged into a single integrated component. This combining of functions allows the structure to provide both mechanical reinforcement and air flow control without the deformation issues that arise from separate joined components. The integrated design eliminates the interface between separate parts that could lead to leakage.
Solution Approach 2:
The reinforcing plate is designed to serve multiple functions: it provides mechanical strength reinforcement to the heat exchanger core and simultaneously acts as a blocking member to control air flow. This multi-functionality eliminates the need for separate components and reduces the risk of leakage at joints.
3Stability of the object's composition
If the top plate is made larger for strength reinforcement, then structural rigidity is improved, but the heat exchanger becomes more complex and harder to manufacture
Solution Approach 1:
Instead of making the entire top plate larger, the reinforcing plate is designed with localized thickness variations and specific geometric features (such as curved surfaces or rib structures) that provide enhanced rigidity only where needed. This local quality approach maintains structural integrity while minimizing overall complexity and manufacturing difficulty.
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 minimizes cooling performance reduction and pressure loss while increasing the structural rigidity of the heat exchanger, preventing air leakage and improving durability.
Implementation Method 1
a core portion (100) comprising an inlet header tank (110) and an outlet header tank (120) having a space, in which cooling water is stored and flows, formed therein
Implementation Method 2
a plurality of tubes (130) having both ends connected to the header tanks (110 and 120) to form a cooling water channel, and fins (140) interposed between the tubes (130)
Data Source
AI summary
Provided is a heat exchanger including a core portion configured to include an inlet header tank and an outlet header tank having a space, in which cooling water is stored and flows, formed therein and formed in a height direction, a plurality of tubes having both ends connected to the header tanks to form a cooling water channel, and fins interposed between the tubes, in which a core portion of the heater exchanger is formed to block only a part of a bypass area of a part where inlet/outlet header tanks are positioned to reduce a pressure loss of air which is a cooled fluid while minimizing a reduction in heat radiation performance of the heat exchanger and structural rigidity of the core portion is increased by a reinforcing structure formed at an outer side of the core portion to improve durability.