Heat Exchanger Manifold Segmentation for Dead Zone Elimination
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Solution Overview
Problem
Heat exchangers with predetermined connection block placement can experience reduced performance due to 'dead zones' when the block is not centrally located, leading to limited fluid flow and requiring additional tubing that compromises external dimensions and heat exchange efficiency.
Innovation Solution
A heat exchanger design with a third section in parallel to the second section, fluidically connected through openings of varying diameters, allowing for optimal placement of inlet and outlet ports and mitigating 'dead zones' by controlling fluid flow between sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the connection block is placed non-centrally to allow flexible inlet/outlet placement, then the adaptability of the heat exchanger is improved, but dead zones occur leading to reduced heat exchange performance
Solution Approach 1:
The manifold is divided into multiple sections (first, second, and third sections) that are fluidically connected through openings. This segmentation allows the fluid to be distributed across different pathways, eliminating dead zones while maintaining flexible connection block placement. The third section specifically receives tubes from the second pass and connects back to the second section, creating additional flow paths that improve heat exchange performance regardless of connection block position.
2Productivity
If additional tubing is added to redirect fluid flow and eliminate dead zones, then the heat exchange performance is improved, but the external dimensions and active area are reduced
Solution Approach 1:
The invention merges the manifold structure with the connection block by integrating the third section directly into the manifold body. The openings that fluidically connect the sections are formed within the manifold itself, eliminating the need for separate additional tubing. This integration maintains the active heat exchange area while achieving the desired flow distribution and eliminating dead zones.
3Productivity
If additional tubing and sealing are added to address flow issues, then the heat exchange performance is improved, but the device complexity and weight increase
Solution Approach 1:
The manifold and connection block are designed as an integrated structure where the third section and its connecting openings are formed as part of the manifold body. This merging eliminates the need for separate tubing components and additional sealing elements, reducing device complexity and weight while maintaining improved heat exchange performance through optimized fluid flow paths.
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 eliminates the need for additional components, reduces the assembly's weight, and ensures uniform fluid flow, improving performance regardless of connection block placement, while maintaining effective heat exchange areas.
Implementation Method 1
heat exchangers with heat exchange tubes and connection blocks
Implementation Method 2
the flow of the heat exchange fluid is limited
Data Source
Figure 1~3
Figure 4~6
Figure 7a~7e
AI summary
A heat exchanger comprising a first manifold and a second manifold connected by tubes, configured to provide at least two passes for a heat exchange fluid between an inlet port and an outlet port located on either of the manifolds, characterised in that for at least one of the passes, at least one of the manifolds comprises a first section adapted to receive the heat exchange fluid directly from the tubes, and a second section which is adapted to receive the heat exchange fluid from the tubes through a third section, the third section being adapted to receive the heat exchange fluid directly from the tubes and being arranged in fluid communication with the second section.