Heat Exchanger Header Fluid Distributor for Uniform Two-Phase Flow
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Solution Overview
Problem
Existing heat exchangers face challenges in uniformly distributing two-phase fluid among multiple ports of microchannel tubes, leading to pressure drops and liquid pool formation within the header.
Innovation Solution
A fluid distributor with a distributor tube having a first and second segment, configured to receive two-phase fluid, where the vapor phase stirs the liquid phase and recirculates it back into the header, preventing pool formation and ensuring uniform distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional fluid distributor is used in the header, then the structure is simple, but the fluid distribution among multiple ports is non-uniform leading to pressure drops and liquid pool formation
Solution Approach 1:
The distributor tube is divided into multiple segments (first tube segment, second tube segment, third tube segment) with different functions. Each segment handles specific fluid distribution tasks, allowing precise control of fluid flow to multiple ports while maintaining a relatively simple overall structure that can be manufactured using standard piping components.
Solution Approach 2:
Different portions of the distributor tube are configured with different properties: the first tube segment has a larger diameter for receiving two-phase fluid, the second tube segment has openings for vapor extraction, and the third tube segment distributes liquid to ports. This local differentiation enables uniform fluid distribution without requiring a completely complex redesign of the entire system.
2Productivity
If the distributor tube extends longitudinally within the header, then fluid can be distributed to multiple ports, but liquid pools form within the header causing pressure drops
Solution Approach 1:
The vapor phase is extracted from the two-phase fluid through openings in the second tube segment. This separation removes the vapor component that would otherwise contribute to liquid pool formation and pressure drops, while allowing the liquid phase to be efficiently distributed to multiple ports through the third tube segment.
Solution Approach 2:
The distributor tube acts as an intermediary device between the header and multiple ports. By positioning the tube segments at specific locations and configuring openings at specific heights, the system mediates the fluid flow to prevent direct pooling in the header while ensuring uniform distribution to all ports.
3Reliability
If vapor phase is extracted through openings in the distributor tube, then liquid pool formation is prevented, but the distributor structure becomes more complex
Solution Approach 1:
The vapor extraction function is isolated to a specific segment (second tube segment) with specific openings, rather than requiring complex modifications to the entire distributor tube. This segmentation allows vapor removal while maintaining the simplicity of other tube segments for liquid distribution.
Solution Approach 2:
Instead of trying to prevent liquid pooling by complex header design or port configuration, the invention inverts the approach by extracting vapor at the source (in the distributor tube itself). This simpler inversion of the conventional approach achieves flow stability without significantly increasing overall system 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
The distributor achieves uniform fluid supply to microchannel tubes with reduced pressure drop and prevents liquid pooling, enhancing heat exchanger performance and efficiency.
Implementation Method 1
a vapor phase associated with the two-phase fluid to flow into the header via the hole
Implementation Method 2
the vapor phase flowing out of the hole into the header facilitates stirring of any pool of the liquid phase formed within the header
Implementation Method 3
causing the two-phase fluid and/or a liquid phase associated with the two-phase fluid to flow out of the distributor into the header via the second open end
Implementation Method 4
when a static pressure created in the header due to a liquid pool formed within the header increases above a pressure created in an interior of the curved portion of the distributor tube due to high velocity of the vapor phase therein, the hole facilitates automated suction of the liquid phase from the formed liquid pool back into the distributor tube
Implementation Method 5
receive a two-phase fluid within the distributor tube via the first open end
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
A fluid distributor 104 for a header 102 is associated with a heat exchanger 100; 500. The distributor 104 comprises a distributor tube 104 comprising a first tube segment 104-A, and a second tube segment 104-B extending at a predefined angle from an end of the first tube segment 104-A, wherein the distributor tube 104 comprises a hole 106 at a predefined position on a predefined side, facing towards the first tube segment 104-A on an inner side of a bend 104-C of the second tube segment 104-B, wherein the distributor tube 104 is configured with the header 102 such that the first tube segment 104-A remains outside of the header 102 and the second tube segment 104-B extends longitudinally within the header 102 via a first end 102-1 of the header 102, with the hole 106 located at the first end 102-1 of the header 102.