Heat Exchanger Coolant Flow Segmentation
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Solution Overview
Problem
Heat exchangers face challenges in increasing cooling capacity without disproportionately increasing flow resistance on the coolant side, which can lead to boiling of the first fluid and reduced thermodynamic efficiency, especially in high-temperature environments, where existing measures like baffle plates increase flow resistance and limit coolant throughput.
Innovation Solution
The heat exchanger design features a main flow running counter or co-current to the first fluid, with strategically arranged flow connections to optimize flow guidance and residence time, including inclined or curved secondary flow paths and connections on different sides of the housing, to enhance cooling efficiency without increasing pressure loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the coolant flow rate is increased to prevent boiling, then the cooling capacity is improved, but the heat exchanger size and flow resistance increase
Solution Approach 1:
The patent divides the coolant flow into two separate flow paths: a first coolant flow that flows through the heat exchanger core in the conventional direction, and a second coolant flow that flows through the housing in a direction opposite to the first fluid flow. This segmentation allows each flow path to be optimized independently, with the second flow providing additional cooling capacity without requiring a proportional increase in overall heat exchanger size.
Solution Approach 2:
The patent utilizes the housing space in a third dimension by directing the second coolant flow through the housing interior rather than through the conventional core channels. This dimensional change allows the system to increase cooling capacity by utilizing previously underutilized space without proportionally increasing the heat exchanger's footprint or flow resistance.
2Ease of operation
If baffle plates are used to guide coolant flow, then the flow guidance is improved, but the coolant-side flow resistance increases
Solution Approach 1:
Instead of using baffle plates to redirect flow, the patent inverts the approach by creating a separate second coolant flow path that naturally flows through the housing in the opposite direction to the first fluid. This inversion eliminates the need for flow-redirection baffles and their associated pressure losses while achieving effective flow guidance.
Solution Approach 2:
The patent extracts the flow guidance function from the conventional baffle plate mechanism and implements it through the housing structure itself. By taking out the need for internal flow redirection elements and using the housing as the flow path, the design reduces flow resistance while maintaining effective coolant guidance.
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 improves thermodynamic efficiency and cooling capacity, particularly in peak temperature areas, by optimizing flow patterns and residence time, while maintaining low flow resistance, thus extending the heat exchanger's lifespan and reducing material stress.
Implementation Method 1
The flow channels are surrounded by coolant in the interior chamber, allowing the coolant to cool the exhaust gas via heat transfer.
Implementation Method 2
cooling hot exhaust gases from internal combustion engines, so that this cooled exhaust gas can be mixed with the intake air
Data Source
Figure 1(A)~2(B)
Figure 3(A)~3(B)
AI summary
The invention relates to a heat exchanger (10, 20, 30) for heat exchange between a first fluid (1), in particular an exhaust gas and/or charge air, and a second fluid (2), in particular a coolant, with a heat exchanger housing (11) comprising: - a housing (12) with flow connections (I, II, III) for the second fluid (2) to a housing interior (15) through which the second fluid (2) flows, - a heat exchanger core (13) which is arranged in the housing interior (15) with a number of flow channels (14) through which the first fluid (1) flows, for the separate and heat-exchanging guidance of the first and the second fluid (1, 2), wherein - the flow connections (I, II, III) are arranged such thatthat in operation - a flow of the second fluid (2) in the housing interior (15) has a main flow 2H running largely parallel to a flow of the first fluid (1) and a secondary flow (2N) running largely in a cross-section transverse to the flow of the first fluid (1). According to the invention, it is provided that (a) the main flow (2H) runs in a direction opposite to the flow of the first fluid (1), or (b) the main flow (2H) runs in a direction of the flow of the first fluid (1), and (i) the secondary flow (2N) has an oblique or curved flow path in the cross-section, and/or (ii) the main flow (2H) is connected to the housing interior (15) by flow connections (I, II, III) on different sides of the housing (12). Furthermore, the invention also relates to a charging system.