Heat Exchanger Outlet Tank Geometry for Lower Pressure Drop
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Solution Overview
Problem
Conventional compact heat exchangers face issues with increased pressure drop and inefficient heat exchange due to reduced heat exchange tubes, leading to higher pump requirements and packaging constraints, with energy losses and increased costs.
Innovation Solution
Incorporation of an inlet, outlet, and intermediate tanks to enhance fluid flow and reduce pressure drop across the heat exchanger by using a tubular element with a larger cross-section and smooth transition to the outlet pipe.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the number of heat exchange tubes is reduced to achieve compactness, then the size of the heat exchanger is reduced, but the pressure drop across the heat exchange tubes increases
Solution Approach 1:
The patent divides the flow path into multiple segments by introducing an intermediate tank and additional tubes. The coolant flow is segmented into parallel paths through the heat exchange tubes and the additional tube, reducing the pressure drop in each individual path while maintaining compact overall dimensions.
Solution Approach 2:
The intermediate tank acts as an intermediary component that redirects coolant flow from the heat exchange tubes to the additional tube. This intermediary structure allows the system to overcome the high pressure drop issue by providing an alternative flow path without requiring a larger overall heat exchanger size.
2Productivity
If the flow velocity of coolant is increased to maintain flow rate with fewer tubes, then the flow rate is maintained, but heat exchange efficiency decreases
Solution Approach 1:
The coolant flow is segmented into multiple parallel channels including heat exchange tubes and an additional tube with larger cross-sectional area. This segmentation allows lower velocity in the additional tube while maintaining overall flow rate, improving heat exchange efficiency without sacrificing productivity.
Solution Approach 2:
The patent changes the cross-sectional area parameter of the additional tube to be larger than individual heat exchange tubes. This parameter change enables the additional tube to carry a significant portion of the flow at lower velocity, thereby improving heat exchange efficiency while maintaining the required overall flow rate.
3Productivity
If the pressure drop across heat exchange tubes is increased to maintain flow rate, then the flow rate is maintained, but a higher capacity pump is required
Solution Approach 1:
The flow path is segmented into parallel channels including multiple heat exchange tubes and an additional tube connected via an intermediate tank. This segmentation creates multiple flow paths that reduce the overall pressure drop, allowing the use of a lower capacity pump while maintaining the required flow rate.
Solution Approach 2:
The intermediate tank serves as a mediator that redistributes coolant flow to the additional tube, creating an alternative path that reduces the pressure drop burden on the pump. This intermediary structure enables flow rate maintenance with reduced pump power requirements.
4Stress or pressure
If an additional tube with larger cross section is used to enhance fluid flow, then the pressure drop is reduced, but the transition from additional tube to outlet pipe causes flow losses
Solution Approach 1:
The outlet tank is designed with a curved, rounded geometry that provides a smooth transition between the rectangular additional tube and the circular outlet pipe. This curved design eliminates abrupt changes in flow direction and cross-section, reducing flow separation and energy losses while maintaining the pressure drop reduction benefits of the larger cross-sectional 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 internal pressure drop, enhances fluid flow efficiency, and lowers the need for a higher capacity pump, making the heat exchanger more compact, cost-effective, and energy-efficient.
Implementation Method 1
there is some extent of heat exchange between the first heat exchange fluid flowing through the additional tube and air flowing outside the additional tube
Implementation Method 2
The smooth transition of the outlet tank shape between those cross-sections along the fluid path reduces flow separation and energy losses
Data Source
Figure 1a
Figure 1b
Figure 2a~2b
AI summary
A heat exchanger includes an inlet tank (10a) connected to and in fluid communication with an inlet pipe (12a) for ingress of a coolant therein, an outlet tank (10b) connected to and in fluid communication with an outlet pipe (12b) for egress of coolant there from. The heat exchanger further includes heat exchange tubes (20) and a tubular element (30) to configure fluid communication between the inlet tank (10a) and the outlet tank (10b). A first side of the outlet tank (10b) is complimentary to and connected to the outlet pipe (12b) and an opposite second side of the outlet tank (10b) is complimentary to and aligned with the tubular element (30). The tubular element (30) and the outlet pipe (12b) are of different cross sections, wherein shape of the outlet tank (10b) transforms smoothly between those cross sections along fluid path.