Heat exchanger unit particularly efficient
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Solution Overview
Problem
Existing heat exchanger systems face performance limitations due to the use of steel/carbon coils, which have lower efficiency compared to copper coils but are more complex and prone to leaks, and bending these coils to increase surface area complicates the structure and increases the risk of leakage and fluid constriction.
Innovation Solution
A coil design for heat exchangers comprising multiple steel/carbon ducts bent in a zig-zag shape and stacked to form thermal exchange walls, with minimal welding to enhance performance per volume unit, reduce leakage risk, and allow for modular assembly and easy maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If copper coils are used to improve heat exchange performance, then thermal efficiency is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent replaces expensive copper coils with steel/carbon coils that are less costly and easier to manufacture. While copper has superior thermal conductivity, the steel/carbon alternative with optimized geometry achieves acceptable performance at lower cost and complexity, aligning with the principle of using simpler, more economical materials when performance requirements allow.
Solution Approach 2:
The patent changes the geometric parameters of the steel/carbon coil, specifically using an inner diameter of 2.6-6.6mm and arranging multiple parallel ducts (2-10 ducts) within a single pipe. This parameter optimization compensates for the lower thermal conductivity of steel/carbon compared to copper, achieving a balance between material properties and geometric design.
2Power
If multiple welding operations are performed to connect copper pipes, then heat exchange performance is improved, but reliability decreases due to increased leakage risk
Solution Approach 1:
The patent divides the heat exchange function into multiple parallel ducts (2-10 ducts) within a single steel/carbon pipe, each duct acting as an independent heat exchange channel. This segmentation allows the system to achieve sufficient total heat exchange area without requiring multiple complex welding connections, as each duct can be manufactured and tested independently before assembly.
Solution Approach 2:
The patent reduces the number of welding operations beforehand in the design stage, which preemptively reduces the potential failure points. By designing a system that achieves its thermal performance goals with fewer connections, the patent eliminates the need for multiple high-risk welding operations that could compromise reliability.
3Area of stationary object
If the coil is bent to increase thermal exchange surface area, then heat exchange performance is improved, but device complexity and fluid flow reliability worsen
Solution Approach 1:
The patent transitions from a two-dimensional planar coil configuration to a three-dimensional arrangement by implementing multiple parallel ducts stacked vertically or horizontally within a single pipe structure. This dimensional change allows the system to achieve increased thermal exchange surface area without requiring complex bending operations, as the multiple ducts provide additional heat exchange pathways in a compact volume.
4Area of stationary object
If the coil is bent to increase thermal exchange surface area, then heat exchange performance is improved, but reliability decreases due to fluid constriction
Solution Approach 1:
The patent segments the fluid flow path into multiple parallel ducts, each with sufficient cross-sectional area to maintain proper refrigerant circulation. By distributing the total heat exchange requirement across multiple ducts rather than relying on a single heavily bent duct, the system maintains adequate fluid flow velocity and pressure throughout, preventing constriction-related reliability issues.
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
This design achieves enhanced thermal exchange capacity per volume unit with reduced leakage risk and modular adaptability, maintaining efficiency while simplifying assembly and maintenance, and is compatible with various refrigeration systems.
Implementation Method 1
a unit for a heat exchanger comprising a coil with pipes designed so as to increase the performance making it similar to that of a heat exchanger with pipes made of copper and fins made of aluminium
Data Source
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AI summary
The present invention relates to a unit for a heat exchanger comprising a coil with pipes designed so as to increase the performance to make it similar to that of a heat exchanger with pipes made of copper and fins made of aluminium. In particular, the invention relates to a coil with an increase of efficiency per surface unit of heat exchange obtained through a simple and reliable construction.