Heat Exchanger De-congealing Channel Design
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Solution Overview
Problem
Heat exchangers face issues during cold start conditions where congealed oil causes high viscosity, leading to pressure losses and system seizing due to low temperatures, and existing solutions restrict geometry and construction.
Innovation Solution
A heat exchanger design featuring corrugated sheets with a de-congealing channel formed by spaces between corrugations, allowing for improved heat transfer and reduced viscosity of oil by providing a larger flow path for warm oil to spread heat across the layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a de-congealing channel is provided to supply warm oil to the heat exchanger matrix, then the oil can be warmed to reduce viscosity and improve flow, but the geometry and construction of the heat exchanger are restricted
Solution Approach 1:
The de-congealing channel is integrated into the existing corrugated sheet structure, allowing the same component to serve both as a heat exchange surface and as a de-congealing passage. The corrugated sheet functions universally as both a heat transfer element and a structural support, eliminating the need for separate de-congealing components and thus maintaining geometric flexibility while achieving reliable de-congealing
Solution Approach 2:
The de-congealing channel is merged with the corrugated sheet structure by utilizing the space between corrugations. This combines the heat exchange function and the de-congealing function into a single integrated structure, allowing warm oil to flow through the corrugated sheet while maintaining the structural integrity and geometric flexibility of the original design
2Area of stationary object
If the corrugations are closely spaced with predetermined period, then the heat exchange surface area is maximized, but the flow resistance increases and de-congealing efficiency decreases
Solution Approach 1:
The corrugated sheet has different local properties: in most areas, the corrugations are closely spaced to maximize heat exchange surface area, while in specific local regions, larger spacing is provided to create de-congealing channels. This local variation in quality allows the structure to optimize both heat transfer and flow characteristics in different zones simultaneously
Solution Approach 2:
The corrugated sheet is segmented into different functional zones: regular corrugation regions for heat exchange and de-congealing channel regions with larger spacing. This segmentation allows the structure to perform multiple functions - heat transfer in regular zones and low-resistance flow in de-congealing zones - without compromising overall performance
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 enhances heat exchange efficiency by reducing flow resistance and facilitating the de-congealing of oil, allowing it to flow more freely and evenly warm the entire layer, thus preventing system seizing and improving performance during cold starts.
Implementation Method 1
When warm liquid flows along the de-congealing channel, it can transfer heat to neighbouring corrugations, which in turn transfer heat to their neighbours and so on, thereby spreading heat through the entire layer and warming all the liquid in the layer
Implementation Method 2
a heat exchanger comprising: a first plurality of layers, each of the first plurality of layers including a corrugated sheet comprising a series of regular corrugations across its width for flow of liquid therethrough
Data Source
AI summary
A heat exchanger and a method for manufacturing a heat exchanger, the heat exchanger comprising: a first plurality of layers, each of the first plurality of layers including: a corrugated sheet comprising a series of regular corrugations across its width for flow of liquid therethrough, the series of corrugations having a predetermined period; and a de-congealing channel for flow of liquid across the width of the corrugated sheet in parallel with the corrugations, the de-congealing channel formed at least in part by two adjacent corrugations, that are separated by greater than the predetermined period.