Interlaced heat exchanger
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Solution Overview
Problem
Existing environmental control systems with multiple heat exchangers often leave a portion of the heat exchange surface area unused during partial load conditions, reducing efficiency and increasing costs due to the need for divider panels and complex fan control algorithms.
Innovation Solution
An interlaced heat exchanger design where microchannel coils or tubes from separate working fluid circuits are arranged in an alternating pattern, allowing all airflow to participate in heat exchange with the operational circuit without dividers, thus maximizing surface area utilization and simplifying fan control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple heat exchangers are separated by divider panels or arranged side-by-side, then circuit separation is achieved, but heat exchange surface area is unused during partial load conditions
Solution Approach 1:
The patent merges multiple heat exchanger circuits into a single integrated unit with alternating coil arrangements. The first and second sets of coils are interlaced within the same housing and airflow path, eliminating the need for physical separation while maintaining circuit independence through separate fluid passages.
Solution Approach 2:
The heat exchanger is segmented into multiple independent coil sets (first set and second set) that can operate independently. Each coil set corresponds to a separate circuit with independent fluid flow paths, allowing selective operation of individual circuits while maintaining a unified physical structure.
2Power
If multiple heat exchangers are arranged side-by-side or stacked, then capacity is increased, but unused surface area occurs during partial load conditions
Solution Approach 1:
The system incorporates dynamic control capabilities where the operational state of each circuit can be independently adjusted. During partial load conditions, only the necessary portion of the heat exchange surface is actively utilized, while the alternating arrangement ensures that airflow efficiently contacts the active coils without being blocked by inactive sections.
Solution Approach 2:
The unified heat exchanger structure serves multiple functions: it provides circuit separation, enables partial load operation, maintains high surface area utilization, and supports variable capacity requirements. The same physical structure adapts to different operational demands by activating or deactivating specific coil sets.
3Reliability
If divider panels are used to separate heat exchangers, then circuit independence is maintained, but system complexity and cost increase
Solution Approach 1:
The patent combines multiple circuit functions into a single integrated heat exchanger assembly. The first and second sets of coils share common structural elements including the housing, airflow path, and mounting structure, eliminating the need for separate assemblies and divider panels while maintaining circuit independence through internal fluid passage design.
4Reliability
If separate heat exchangers are used for multiple circuits, then circuit isolation is achieved, but fan control complexity increases
Solution Approach 1:
The unified heat exchanger structure enables a single fan to serve multiple circuits efficiently. The alternating coil arrangement ensures that airflow generated by one fan can effectively contact coils from different circuits in sequence, eliminating the need for multiple fans or complex control algorithms while maintaining circuit isolation through the internal fluid passage design.
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 interlaced heat exchanger enhances efficiency by ensuring all airflow engages with the operational circuit, even when other circuits are not in use, and simplifies fan control, reducing costs and improving thermal energy distribution.
Implementation Method 1
a heat exchanger that is configured to exchange thermal energy, such as heat, between a working fluid flowing through conduits or coils of the heat exchanger and an airflow flowing across the conduits or coils
Implementation Method 2
exchange thermal energy, such as heat, between a working fluid flowing through conduits or coils of the heat exchanger and an airflow flowing across the conduits or coils
Data Source
AI summary
Embodiments of the present disclosure are directed to a climate management system that includes a heat exchanger having a first set of microchannel coils fluidly coupled to a first circuit of the climate management system and a second set of microchannel coils fluidly coupled to a second circuit of the climate management system, where the first circuit and the second circuit are fluidly separate from one another, and where the first set of microchannel coils and the second set of microchannel coils are disposed in an alternating arrangement along a length of the heat exchanger such that the first set of microchannel coils and the second set of microchannel coils are interlaced in the heat exchanger.