Water-cooled heat exchanger

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Solution Overview

Problem

Current chillers with water-cooled heat exchangers face inefficiencies due to the use of copper pipes and silver brazing, which complicate assembly and increase manufacturing complexity, while also experiencing pressure drops and thermal property changes in refrigerant distribution.

Innovation Solution

An integrated oil separator with a distributor and filter media cartridges within a steel pipe assembly, using welding instead of silver brazing, maintains consistent pressure and thermal properties by distributing refrigerant evenly without additional pressure drops.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If copper pipes and silver brazing are used to connect compressor discharge flows with oil separator, then assembly is achieved, but manufacturing complexity increases and assembly is complicated

Engineering Contradiction:

Improveassembly processVSAvoidmanufacturing complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The distributor is integrated directly into the oil separator body, merging two previously separate components (distributor and oil separator) into a single unit. This eliminates the need for separate copper pipes and silver brazing connections, simplifying both manufacturing and assembly processes while reducing the number of joints required

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The oil separator body is designed to serve multiple functions: it acts as both the oil separator housing and the distributor for refrigerant distribution. This multi-functional design eliminates the need for separate copper pipe connections, reducing manufacturing complexity and assembly steps

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If copper pipes and multiple connections with silver brazing are used, then refrigerant distribution is achieved, but pressure drops and thermal property changes occur

Engineering Contradiction:

Improverefrigerant pressure consistencyVSAvoidnumber of connections

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

By integrating the distributor into the oil separator body, the invention eliminates multiple separate connections and joints. This reduces the number of potential leak points and pressure drop locations, maintaining more consistent refrigerant pressure and thermal properties throughout the system

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention removes the external copper pipe connections and silver brazing joints from the system by integrating the distributor function directly into the oil separator body. This extraction of unnecessary connections eliminates the associated pressure drops and thermal property changes

Inventive Principle:

Principle #2Taking out (Extraction)

3Ease of manufacture

If integrated distributor within exterior shell is used, then manufacturing is simplified, but structural design complexity increases

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidstructural design

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The integrated distributor is designed with a modular structure featuring longitudinal slots that segment the internal flow paths. This segmentation allows for simplified manufacturing of the distributor component while maintaining effective refrigerant distribution, balancing structural design complexity with manufacturing ease

Inventive Principle:

Principle #1Segmentation

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

Simplifies manufacturing, reduces material thickness, and maintains refrigerant pressure and thermal efficiency by eliminating the need for complex copper-copper and copper-steel joints, allowing for easier assembly and reduced material usage.

Implementation Method 1

first and second filter media cartridges (41, 42) disposed within the first interior between the opposite spaces and the second opening

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Implementation Method 2

distributor integrated within the exterior shell to define a second interior within the first interior... form first and second passageways from the first opening to the opposite spaces

Methodology Applied

Scientific EffectFluid distribution through controlled flow paths:

Implementation Method 3

using welding instead of silver brazing

Methodology Applied

Scientific EffectWelding: Welding

Implementation Method 4

water-cooled heat exchanger

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentEP3803233B1Water-cooled heat exchanger

Publication Date: 2024.03.06 CARRIER CORP

Figure 1
Figure 2~3
Figure 4~6

AI summary

An oil separator is provided and includes an exterior shell defining a first interior and first and second openings fluidly communicative with the first interior, a distributor and first and second filter media cartridges. The distributor is integrated within the exterior shell to define a second interior within the first interior, has a length, which is slightly less than that of the exterior shell, being disposed to define opposite spaces between opposites ends thereof and opposite ends of the exterior shell and is sealed to the exterior shell along the length to form first and second passageways from the first opening to the opposite spaces. The first and second filter media cartridges are disposed within the first interior between the opposite spaces and the second opening.