U-Flow Heat Exchanger Deflection Area Cooling
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Solution Overview
Problem
U-flow heat exchangers suffer from inadequate cooling of the deflection area and low maximum heat transfer, leading to inefficiencies in heat transfer performance.
Innovation Solution
A heat exchanger design featuring a temperature-controlled deflection area with a second fluid flowing around the first flow channel, which includes tubes and a multi-part housing to enhance heat transfer and reduce pressure loss, utilizing turbulence inserts and a fluid-tight seal to optimize flow and heat exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the heat exchanger uses a U-shaped flow channel to deflect fluid by approximately 180 degrees, then the cooling distance is doubled over the same overall length, but the cross section per cooling section is reduced leading to increased pressure loss
Solution Approach 1:
The flow channel is divided into multiple cooling sections with individual deflectors, allowing each section to maintain adequate cross-sectional area while collectively providing extended cooling distance. The segmentation enables parallel heat transfer paths that reduce overall pressure loss.
Solution Approach 2:
The deflection is achieved not only through U-shaped routing but also by utilizing the third dimension with vertically arranged cooling sections and deflectors positioned at different heights, maintaining cross-sectional flow area while extending cooling path length.
2Ease of manufacture
If the deflection area is not cooled or only cooled by surrounding air, then the structure is simple, but the maximum heat transfer is insufficient
Solution Approach 1:
The deflection area is merged with the cooling system by integrating a second cooling section that directly cools the deflection region, combining the flow deflection function with heat transfer function in a unified structure.
Solution Approach 2:
The housing and cooling sections serve multiple functions: they contain the fluid flow, provide structural support, and actively cool the deflection area through the second cooling section, making the system multi-functional.
3Ease of manufacture
If a single-piece deep-drawn housing is used, then the manufacturing process is simple, but undercuts cannot be realized limiting housing shape adaptation
Solution Approach 1:
The housing is divided into multiple separable parts that can be independently manufactured and then assembled, enabling complex geometries with undercuts that cannot be produced in a single deep-drawing operation.
Solution Approach 2:
The multi-part housing design allows nested assembly where individual housing sections fit together, creating complex overall shapes while each part remains manufacturable with standard processes.
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 improves heat transfer efficiency by fully involving the deflection area in heat transfer, increasing the overall heat transfer surface and maintaining low pressure loss, resulting in enhanced performance compared to prior art.
Implementation Method 1
a second fluid flows around the first flow channel in the area of the inflow section, in the area of the return flow section and in the area of the deflection, as a result of which a heat transfer is achieved between the fluid within the flow channel and the fluid flowing around the flow channel
Implementation Method 2
A plurality of tubes, around which a fluid flows on their outer surfaces, can increase the heat transfer surface overall, as a result of which improved heat transfer between the fluid inside the tubes and the fluid outside the tubes can be achieved
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a heat exchanger (1, 21, 41, 81) with a first flow channel (15, 39, 55, 100) through which a first fluid can flow, and with a second flow channel (14, 38, 54, 99) through which a second fluid can flow, wherein the first flow channel (15, 39, 55, 100) has a first subsection (12, 36, 52, 97), a second subsection (13, 37, 53, 98) and a deflection area, wherein the first subsection is in fluid communication with the second subsection via the deflection area (7, 27, 47, 87) and the first subsection (12, 36, 52, 97), the second subsection (13, 37, 53, 98) and the deflection area (7, 27, 87) 47, 87) are surrounded by the second fluid, wherein the first subsection (12, 36, 52, 97) and/or the second subsection (13, 37, 53, 98) of the first flow channel (15, 39, 55, 100) is each formed by a plurality of tubes (8, 9, 28, 29, 48, 49, 88, 89).