Heat exchanger with variable tube length
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Solution Overview
Problem
Current car air conditioner condensers face challenges in enhancing refrigerant condensation efficiency and subcooling efficiency, with existing designs not fully optimizing the length and arrangement of heat exchange tubes and corrugated fins to maximize these processes.
Innovation Solution
A heat exchanger design featuring heat exchange tubes of varying lengths with corrugated fins that differ in length and arrangement to accommodate both shorter and longer tubes, allowing for improved refrigerant flow and separation within a compact structure, utilizing header tanks to separate gas and liquid phases by gravity, and optimizing the placement of corrugated fins to enhance efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If heat exchange tubes of uniform length are used, then manufacturing and assembly are simplified, but refrigerant condensation efficiency and subcooling efficiency cannot be optimized
Solution Approach 1:
The heat exchange tube group is segmented into multiple tube groups (first, second, third tube groups) with different tube lengths. Each tube group contains tubes of a specific length, allowing the system to optimize heat exchange efficiency for different refrigerant flow paths while maintaining manageable manufacturing and assembly processes through modular grouping.
Solution Approach 2:
Different regions of the heat exchanger are assigned different tube lengths based on local requirements. The first tube group has shorter tubes suitable for certain flow paths, while the second and third tube groups have longer tubes for other paths. This local differentiation optimizes refrigerant condensation and subcooling efficiency in each specific region.
2Productivity
If heat exchange tubes of varying lengths are used, then refrigerant condensation and subcooling efficiency are improved, but device complexity increases
Solution Approach 1:
The complex arrangement of varying tube lengths is managed by segmenting the tubes into distinct groups (first, second, third tube groups) where each group contains tubes of uniform length. This segmentation reduces the overall complexity by creating manageable modules rather than requiring completely individual customization of each tube.
Solution Approach 2:
The heat exchange tubes are designed with multi-functionality to reduce complexity. The same basic tube structure and corrugated fin design are used across different tube groups, with only the length varying. This universal design approach allows the system to achieve varying lengths without proportionally increasing structural complexity.
3Productivity
If corrugated fins are customized for each tube length variation, then heat exchange efficiency is maximized, but manufacturing complexity and cost increase
Solution Approach 1:
The corrugated fins are designed with local quality variations - specifically, the number of crest portions is adjusted based on the local tube length requirements. Fins for longer tubes have more crest portions, while fins for shorter tubes have fewer crest portions. This localized optimization maintains heat exchange efficiency without requiring complete customization of each fin.
Solution Approach 2:
The design optimizes heat exchange efficiency by changing key parameters of the corrugated fins, such as the number of crest portions and the length of the fin, to match different tube lengths. This parameter adjustment approach allows for efficient heat exchange across varying tube lengths while maintaining a systematic manufacturing process based on standardized fin designs.
4Volume of moving object
If the heat exchanger is designed for compact installation, then space utilization is improved, but the arrangement of varying tube lengths and fins becomes more difficult
Solution Approach 1:
The heat exchanger utilizes three-dimensional space efficiently by arranging tube groups and corrugated fins in multiple dimensions. The first, second, and third tube groups are positioned at different locations and orientations, with corrugated fins extending between tubes in various directions. This dimensional arrangement achieves compact volume while systematically managing the complexity of varying tube lengths.
Solution Approach 2:
The design employs a nested arrangement where corrugated fins are positioned between and around heat exchange tubes in a compact configuration. The fins nest within the available space between tubes of different lengths, maximizing space utilization while maintaining a structured arrangement that manages complexity through systematic positioning.
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 design improves refrigerant condensation and subcooling efficiencies by allowing for tailored fin lengths and arrangements, enabling efficient gas-liquid separation and compact installation, while maintaining consistent subcooling performance across varying refrigerant charges.
Implementation Method 1
The second header tank is disposed on the outer side of the first header tank with respect to the left-right direction, and the upper end of the second header tank is located above the lower end of the first header tank. The second header tank has a function of separating gas and liquid from each other and storing the separated liquid.
Data Source
AI summary
A heat exchanger includes a plurality of heat exchange tubes and corrugated fins. The heat exchange tubes are spaced apart from one another in a vertical direction of the heat exchanger. The corrugated fins are each disposed between adjacent heat exchange tubes. Each of the corrugated fins includes crest portions, trough portions, and connection portions. The crest portions extend in an air passage direction of the heat exchanger. The trough portions extend in the air passage direction. The connection portions connect the crest portions and the trough portions. The number of the crest portions of each of the corrugated fins disposed between adjacent heat exchange tubes falls within a range of a designed number ±2. The designed number is a standard number.