Integrated Heat Exchanger Subcooler for Liquid Refrigerant Quality
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Solution Overview
Problem
Vapor-compression cooling systems face inefficiencies due to suboptimal quality of the liquid refrigerant entering the expansion device, which affects overall system performance.
Innovation Solution
A heat exchanger assembly with micro-channel tubes and headers that includes a supply conduit routing through the outlet header, facilitating subcooling of refrigerant vapor into a liquid state before expansion, enhancing the refrigerant's quality by thermal transfer between liquid and vapor phases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional condenser and expansion device arrangement is used, then the system structure is simple, but the quality of liquid refrigerant entering the expansion device is suboptimal, reducing system efficiency
Solution Approach 1:
The patent combines the condenser and subcooler functions into a single integrated heat exchanger assembly. The condenser section condenses refrigerant vapor to liquid, while the subcooler section further cools the liquid refrigerant before it enters the expansion device. This merging of functions into one component improves system efficiency by ensuring high-quality subcooled liquid refrigerant enters the expansion device, while avoiding the need for separate condenser and subcooler components.
Solution Approach 2:
The integrated heat exchanger is divided into distinct functional sections: a condenser section with first plurality of tubes, a subcooler section with second plurality of tubes, and associated headers. This segmentation allows each section to perform its specific function optimally while being part of a unified structure, enabling efficient heat transfer for both condensation and subcooling processes.
2Productivity
If the refrigerant is not subcooled before expansion, then the system complexity is reduced, but the cooling performance and efficiency deteriorate
Solution Approach 1:
The patent integrates the subcooling function within the condenser assembly by adding a subcooler section with a second plurality of tubes and associated headers. This allows the liquid refrigerant to be further cooled after condensation, improving the quality of refrigerant entering the expansion device and enhancing cooling performance, while maintaining a unified heat exchanger structure.
3Reliability
If a separate subcooler component is added to improve refrigerant quality, then the refrigerant quality improves, but the device complexity and space requirements increase
Solution Approach 1:
The patent merges the subcooler with the condenser into a single integrated heat exchanger assembly. The subcooler section with its second plurality of tubes and headers is integrated alongside the condenser section, allowing high-quality subcooled liquid refrigerant to be produced without requiring a separate standalone subcooler component, thus maintaining system compactness.
4Reliability
If the heat exchanger uses separate sections for condensation and subcooling, then the refrigerant quality is maximized, but the manufacturing complexity increases
Solution Approach 1:
The heat exchanger is segmented into a condenser section with first tubes and headers, and a subcooler section with second tubes and headers. This segmentation allows each section to be optimized for its specific function while being manufactured as an integrated assembly, balancing manufacturing feasibility with performance requirements.
Solution Approach 2:
The integrated heat exchanger assembly performs multiple functions: condensation of refrigerant vapor to liquid in the condenser section, and further subcooling of the liquid refrigerant in the subcooler section. This multi-functionality is achieved within a single manufactured assembly, avoiding the need for multiple separate components and simplifying the overall manufacturing process.
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
Improves the efficiency of vapor-compression cooling systems by maximizing the quality of the liquid refrigerant entering the expansion device, leading to enhanced cooling performance and system efficiency.
Implementation Method 1
The supply conduit includes a conduit portion extending through the outlet header... The liquid conduit is thermally coupled to the suction header for heat transfer between liquid refrigerant in the liquid conduit and the vapor refrigerant in the suction header
Implementation Method 2
heat transfer between liquid refrigerant in the liquid conduit and the vapor refrigerant in the suction header
Implementation Method 3
facilitating subcooling of refrigerant vapor into a liquid state before expansion, enhancing the refrigerant's quality by thermal transfer between liquid and vapor phases
Data Source
AI summary
A heat exchanger assembly includes a plurality of tubes, each having an inlet end and an outlet end. An inlet header is configured to receive a cooling fluid and to distribute the cooling fluid to the inlet ends of the plurality of tubes. An outlet header includes an outer shell and defines an outlet chamber. The outlet chamber is configured to receive cooling fluid discharged from the outlet ends of the plurality of tube. A supply conduit supplies the cooling fluid to the inlet header. The supply conduit includes a conduit portion extending through the outlet header.