Heat exchanger for HVAC unit
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Solution Overview
Problem
Existing heat exchangers for HVAC systems are costly due to the high number of conduits and headers required to increase capacity, leading to elevated manufacturing costs.
Innovation Solution
A heat exchanger configuration with a reduced number of conduits and headers, utilizing a support plate and integrated header with separate passages to maintain thermal efficiency while minimizing material usage, including a bend that couples conduit portions and fins to support weight and enhance airflow contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the number of conduits and headers is increased to increase heat exchanger capacity, then thermal energy transfer capacity is improved, but manufacturing cost increases
Solution Approach 1:
The patent merges multiple conduit functions into fewer conduits by implementing U-shaped configurations that serve both as supply and return paths, eliminating the need for separate parallel conduits and reducing overall component count while maintaining heat transfer capacity
Solution Approach 2:
Each conduit is designed to perform multiple functions: serving as both supply and return passages, providing structural support, and acting as a mounting surface for fins, thereby reducing the total number of components needed
2Ease of manufacture
If the number of conduits is reduced to decrease manufacturing cost, then manufacturing cost is improved, but heat exchanger capacity may be compromised
Solution Approach 1:
The patent extends fins in multiple directions (perpendicular to conduits and along conduit lengths) to increase heat transfer surface area compensating for reduced conduit count, utilizing three-dimensional space efficiently to maintain capacity with fewer components
Solution Approach 2:
The patent modifies fin parameters including extending fin length, increasing fin density, and optimizing fin spacing to maximize heat transfer surface area and efficiency, compensating for the reduced number of conduits while maintaining overall heat exchanger capacity
3Power
If fins are added to increase heat transfer surface area, then thermal energy transfer efficiency is improved, but device complexity increases
Solution Approach 1:
The patent combines the fin support function with the conduit structure itself, using conduits as inherent mounting surfaces for fins, thereby eliminating the need for separate support structures and reducing overall device complexity while maximizing heat transfer surface area
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 solution reduces the overall cost of the heat exchanger without significantly compromising its capacity, by increasing airflow flow rates and modifying fin configurations to maintain thermal energy transfer efficiency.
Implementation Method 1
the heat exchanger that is configured to exchange thermal energy, such as heat, between a working fluid flowing through conduits of the heat exchanger and an airflow flowing across the conduits
Implementation Method 2
an airflow flowing across the conduits... facilitate the transfer of thermal energy between the working fluid and the airflow
Implementation Method 3
the heat exchanger may include fins that are positioned between conduits to facilitate the transfer of thermal energy between the working fluid and the airflow
Data Source
AI summary
Embodiments of the present disclosure are directed to a heat exchanger system that includes a conduit configured to flow a working fluid therethrough, where the conduit has a first portion, a second portion, and a bend directly coupling the first portion and the second portion, where the first portion includes a first header connection, the second portion includes a second header connection, and the bend is distal to the first header connection and the second header connection and a support plate coupled to the bend and positioned between the first portion and the second portion of the conduit.