Helical Heat Exchanger With Internal Heater for Rapid Temperature Control
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Solution Overview
Problem
Existing heat exchanger systems face inefficiencies and high costs due to slow response times and large volume requirements, particularly in semiconductor manufacturing where precise temperature control is needed, and they often require extensive piping and fittings, making them costly and inefficient.
Innovation Solution
A versatile three-way heat exchanger design featuring a helically wrapped tubing configuration with an internal electrical heater, allowing for efficient heat transfer between a refrigerant and a thermal transfer fluid, enabling rapid temperature changes and compact, cost-effective operation by using a single system for both heating and cooling with minimal additional plumbing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional heat exchanger systems are used, then temperature control functions can be provided, but response time is slow and system volume is large
Solution Approach 1:
The patent implements a nested configuration where the refrigerant tube is positioned inside the thermal transfer fluid passage. The refrigerant tube carries refrigerant flow while being surrounded by thermal transfer fluid that flows in the annular space between the refrigerant tube and the outer housing. This nested arrangement maximizes heat transfer surface area within a compact volume, enabling rapid temperature changes without requiring large system volume.
2Measurement precision
If separate heating and cooling systems are used, then temperature control precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent creates a universal heat exchanger system that can perform both heating and cooling functions through a single integrated design. The refrigerant tube and thermal transfer fluid passage configuration allows the system to transfer heat in either direction depending on the temperature differential between the refrigerant and thermal transfer fluid. This multi-functional approach eliminates the need for separate heating and cooling systems, reducing device complexity while maintaining temperature control precision.
3Ease of manufacture
If extensive piping and fittings are used, then fluid media can be transported, but manufacturing cost and system complexity increase
Solution Approach 1:
The patent merges multiple functions into a single integrated heat exchanger assembly. The housing simultaneously serves as a structural component, a fluid passage for thermal transfer fluid, and a containment for the refrigerant tube. The refrigerant tube is directly coupled to the housing, eliminating the need for separate piping and fittings to connect these components. This consolidation reduces both manufacturing cost and system complexity while maintaining effective heat transfer.
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 provides a compact, efficient, and cost-effective system capable of rapid temperature changes, maintaining precise control over a wide temperature range while reducing system volume and costs, with high heat transfer coefficients and the ability to withstand high pressures and temperatures.
Implementation Method 1
Thermal energy transfer takes place directly through the walls of the tubing
Implementation Method 2
The thermal transfer fluid flows at a relatively high velocity confined within its helical path
Implementation Method 3
The center tube has an open interior which can receive a cylindrical electric heater for increasing the temperature of the thermal transfer fluid
Implementation Method 4
Cooling is most typically supported by a vapor-cycle refrigerator in evaporating a condensed fluid to vapor
Implementation Method 5
The heat exchanger effects the transfer of heat from the heat transfer fluid to the refrigerant
Data Source
AI summary
A compact heat exchanger for interchanging thermal energy between at least two fluids, one of which fluids may be a refrigerant in hot or cold form or in a liquid/vapor phase, and another of which fluids is a thermal transfer fluid. The heat exchanger may incorporate an internal heating element. The thermal transfer fluid is transported between two concentric metal tubes, while the refrigerant moves along a tubing helically wrapped about or between the tubes and is in thermal contact therewith.