Heat Exchanger Manifold Segmentation for Uniform Tube Flow
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Solution Overview
Problem
Existing heat exchangers face issues with non-uniform distribution of heat exchange fluid across tubes, leading to increased pressure drop, thermal efficiency reduction, and thermal shock, necessitating higher power consumption and system size.
Innovation Solution
A heat exchanger design with a manifold system that divides the first pass into two channels, each connected to distinct sets of tubes, ensuring uniform fluid flow without increasing pressure drop, using parallel stacks and U-turns to enhance distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the first pass of heat exchange tubes is divided into two passes to improve uniform flow distribution, then uniform distribution of heat exchange fluid is improved, but pressure drop in the heat exchange fluid is increased
Solution Approach 1:
The first pass of heat exchange tubes is divided into two separate passes with separate channels. Each channel connects to a specific set of tubes, allowing independent flow control and distribution. This segmentation enables uniform fluid distribution across all tubes while maintaining manageable pressure drop levels by preventing flow competition between channels.
2Productivity
If the first pass of heat exchange tubes is divided into two passes to achieve uniform distribution, then thermal efficiency is improved, but system cost and size increase due to higher power pump requirements
Solution Approach 1:
By segmenting the first pass into two separate channels with dedicated tube sets, the system achieves uniform flow distribution and improved thermal efficiency without requiring oversized pumps. Each channel operates independently at optimal flow rates, eliminating the need for high-power pumps that would be required if a single pass handled all tubes uniformly.
3Stress or pressure
If non-uniform distribution of heat exchange fluid occurs across heat exchange tubes, then pressure drop is reduced, but thermal efficiency decreases and thermal shock occurs in some tubes
Solution Approach 1:
The heat exchange tubes are segmented into multiple groups, each served by a dedicated channel. This ensures uniform fluid distribution across all tube groups, preventing thermal shock by eliminating flow imbalances while maintaining appropriate pressure drop levels through controlled channel design.
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
Uniform fluid distribution enhances thermal efficiency and prevents thermal shock, extending the service life of the heat exchanger while maintaining system size and cost.
Implementation Method 1
the first channel is directly connected to the inlet and a first set of tubes amongst the first section of tubes, while the second channel is directly connected to the inlet and a second set of tubes amongst the first section of tubes
Implementation Method 2
heat exchangers are used in many applications to exchange heat between two or more fluids
Implementation Method 3
the refrigerant flow path can defined through the heat exchange elements provided in the heat exchanger
Data Source
AI summary
A heat exchanger including: a first manifold including an inlet for a heat exchange fluid, at least one first channel and at least one second channel; a second manifold spaced apart from the first manifold; and a plurality of heat exchange tubes fluidically connecting the first manifold and the second manifold. The plurality of heat exchange tubes is divided into a first section of tubes and a second section of tubes. The at least one first channel is directly connected to the inlet and a first set of tubes amongst the first section of tubes, while the at least one second channel is directly connected to the inlet and a second set of tubes amongst the first section of tubes. The first manifold is adapted to prevent the fluid from travelling between the at least one first channel and the at least one second channel within the first manifold.