Helical Heat Exchange Cell Layout for Compact Condensing Flow
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Solution Overview
Problem
Existing heat exchange cells face inefficiencies in thermal power delivery and installation flexibility due to suboptimal heat exchange between combustion gases and the heat transfer fluid, leading to increased axial size and reduced condensing capacity.
Innovation Solution
A heat exchange cell design featuring a helically-shaped heat exchanger with a separating element mounted externally, allowing parallel fluid flow between collection chambers and optimizing fluid dynamics to enhance heat exchange efficiency and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a helically-shaped heat exchanger is used to increase heat exchange surface area, then heat exchange efficiency is improved, but axial size increases
Solution Approach 1:
The patent implements a nested structure where the helical heat exchanger is positioned within a containment casing that includes internal collection chambers. The separator element creates nested regions for different fluid flows, allowing the heat exchanger to be compactly integrated while maintaining efficient heat transfer surface area without excessive axial extension.
Solution Approach 2:
The patent transitions from a simple linear heat exchanger configuration to a three-dimensional helical structure with radial and axial components. The helical coils are arranged to optimize heat exchange in multiple spatial dimensions, allowing compact packaging of large heat transfer surface area within a constrained axial footprint.
2Device complexity
If combustion gases flow directly from first collection chamber to outside, then device complexity is reduced, but heat exchange efficiency decreases
Solution Approach 1:
The patent introduces a second collection chamber as an intermediary between the first collection chamber and the external environment. Combustion gases flow sequentially through the first collection chamber (where initial heat exchange occurs), then through the second collection chamber (where additional heat exchange occurs), before exiting. This intermediary chamber enables enhanced thermal power delivery while maintaining relatively simple structural implementation.
3Productivity
If separator element is mounted internally to create second collection chamber, then heat exchange efficiency is improved, but device complexity increases
Solution Approach 1:
The separator element serves multiple functions simultaneously: it physically divides the containment casing to create the second collection chamber, acts as a structural support for the helical heat exchanger, and facilitates the sequential flow path for combustion gases. This multi-functionality enables improved condensing capacity without proportionally increasing device complexity.
4Power
If heat exchanger axial extension is increased to improve heat exchange, then thermal power delivery is improved, but installation flexibility is reduced
Solution Approach 1:
The helical heat exchanger is nested within the containment casing with the second collection chamber, allowing the heat exchange surface to be distributed in a compact three-dimensional arrangement rather than requiring long axial extension. This nested configuration maintains high thermal power delivery while reducing the overall axial footprint for improved installation flexibility.
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 achieves higher thermal power delivery with reduced axial size and improved installation flexibility, while minimizing axial extension and enhancing condensing capacity.
Implementation Method 1
the heat exchange cell is to heat water circulating inside the heat exchanger mounted in the cell by means of hot combustion gases
Implementation Method 2
the second heat transfer fluid tends to flow through the interstices between the coils in a substantially radial or axial-radial direction, thus transferring heat to the first heat transfer fluid circulating inside the duct
Implementation Method 3
the heat exchange cells of the condensation type are for example configured to use both the heat developed as a result of combustion, and the latent condensation heat contained in the combustion gases
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
A heat exchange cell is described comprising a containment casing (11) comprising a rear wall (11d), a front wall (22) and a peripheral side wall (11c), a helically-shaped heat exchanger (13) comprising at least one tubular duct for the flow of a first heat transfer fluid coiled about a longitudinal axis of the helix according to a plurality of coils and mounted in the containment casing (11); a feeding zone of a second heat transfer fluid, intended for the heat exchange with the first heat transfer fluid, defined in the casing (11) coaxially and internally with respect to the heat exchanger (13); a first chamber (15) for collecting the second heat transfer fluid externally defined with respect to the heat exchanger (13) between a radially outer wall thereof and the peripheral side wall (11c) of the containment casing (11); and a second chamber (16) for collecting the second heat transfer fluid at least partially delimited by at least one separating element (14). The separating element (14) is mounted at an axially external position with respect to the heat exchanger (13) in such a way as to define the second chamber (16) for collecting the second heat transfer fluid between the separating element (14), the peripheral side wall (11c) and the rear wall (11d) or the front wall (22) of the containment casing (11); in this way, the first (15) and the second (16) collection chambers are in fluid communication with each other by means of at least one passage (17a, 17a', 17b-17g; 14e) configured to allow a flow of the second heat transfer fluid substantially in parallel to the peripheral side wall (11c) of the casing (11) and in proximity thereto. The separating element (14) comprises a heat exchange portion in contact with at least one portion of an end coil of the heat exchanger (13) and configured to allow a heat exchange between the coil-shaped portion of the heat exchanger (13) and the second collection chamber (16), while the heat exchange cell (10) further comprises at least one second passage (35) allowing a fluid outlet from the second collection chamber (16) peripherally defined in the second chamber (16) between an axial end (11g) of the peripheral side wall (11c) and the rear wall (11d) or the front wall (22) of the containment casing (11).