Heat Exchanger Plate Flow Distribution
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Solution Overview
Problem
Existing water-cooled charge air coolers (WCACs) face issues with uneven distribution of air among core tubes due to the shape of the inlet header tank, leading to suboptimal performance.
Innovation Solution
The implementation of fluid flow restricting means on the inlet core plate with differentiated restrictions, such as apertured portions, to manage fluid flow passages with varying cross-sections, ensuring even distribution among all channels and runners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the inlet header tank shape is optimized to improve flow distribution, then air distribution among core tubes improves, but the solution is insufficient and flow unevenness persists
Solution Approach 1:
The patent applies local quality by placing fluid flow restricting means at specific locations on the inlet core plate where flow rate is expected to be higher. The restrictions are not uniformly distributed but are strategically positioned to create localized flow control, allowing different parts of the inlet to have different flow characteristics to achieve overall uniform distribution.
Solution Approach 2:
The patent changes the flow resistance parameter by introducing restricting means with varying degrees of restriction across different areas of the inlet core plate. By modifying the flow resistance parameter locally rather than changing the global inlet geometry, the patent achieves better flow distribution with a simpler overall design.
2Manufacturing precision
If narrower restrictions are placed at areas with higher expected flow rate, then flow distribution becomes more even, but the device complexity increases
Solution Approach 1:
The patent merges the flow distribution function with the existing inlet core plate structure. The restricting means are integrated into the inlet core plate itself rather than being separate components, combining the plate's structural function with its flow distribution function. This reduces overall device complexity while achieving the desired flow control.
Solution Approach 2:
The inlet core plate is given multiple functions: it serves as both a structural support element and a flow distribution device. By making the inlet core plate universal (performing both structural and flow control functions), the patent avoids adding separate components that would increase device complexity.
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 approach optimizes air distribution across all core tubes and runners, enhancing the performance of the heat exchanger by ensuring a more uniform flow, which can improve engine efficiency.
Implementation Method 1
fluid flow restricting means on the inlet core plate (11) in such a way that the restrictions (71) cooperate with the openings (11a) of the inlet core plate (11) to define fluid flow passages having different flow cross-sections
Data Source
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AI summary
A heat exchanger comprising: a plurality of parallel tubes (31) for conveying a fluid, inlet and outlet core plates (11, 21), each having a plurality of openings into which respective ends of the tubes are inserted in a fluid-tight manner, and inlet and outlet header tanks (13, 23) joined to the inlet and outlet core plates (11, 21), respectively, in a fluid-tight manner, the inlet and outlet header tanks cooperating with the inlet and outlet core plates to form a fluid inlet chamber and a fluid outlet chamber, respectively. A fluid flow restrictor is provided on the inlet core plate (11), the fluid flow restrictor placing differentiated restrictions (71) in front of the openings (11a) of the inlet core plate (11) in such a way that the restrictions (71) cooperate with the openings (11) of the inlet core plate (11a) to define fluid flow passages having different flow cross-sections.