Microchannel Heat Exchanger Layout for Space-Filling Auxiliary Cores
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Solution Overview
Problem
Microchannel heat exchangers face packaging constraints in heating and cooling systems, where inlet and outlet plumbing limits the volume allocation for the heat exchanger core, reducing the overall heat transfer capability due to unoccupied regions and restricted orientation, shape, and size.
Innovation Solution
A microchannel heat exchanger configuration with a primary and secondary core, interconnects, and fins, allowing for a secondary core to occupy unoccupied regions and enabling bending into shapes like A-shape, M-shape, or V-shape to increase heat transfer surface area within a given volume, while maintaining efficient fluid distribution and flow characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If inlet and outlet plumbing is used to connect heat exchanger cores, then fluid distribution is achieved, but the plumbing occupies volume that could be used for heat transfer surface area
Solution Approach 1:
The patent combines the plumbing function with the heat transfer function by making the headers themselves part of the heat exchanger core. The first and second headers are thermally coupled to the microchannel tubes, allowing them to serve both as fluid distribution elements and as heat transfer surfaces, thereby eliminating the need for separate plumbing that would occupy additional volume.
Solution Approach 2:
The headers perform multiple functions: they distribute fluid to the microchannel tubes and simultaneously act as heat transfer surfaces. This multi-functionality maximizes the use of available volume for heat transfer while maintaining efficient fluid distribution throughout the core.
2Volume of stationary object
If a single core configuration is used, then manufacturing is simplified, but the heat transfer surface area within available volume is limited due to unoccupied regions
Solution Approach 1:
The heat exchanger core is divided into multiple discrete cores (first core and second core), each with its own headers and microchannel tubes. This segmentation allows the cores to be arranged to fill unoccupied regions more effectively, increasing the overall heat transfer surface area within the available volume while maintaining manufacturing simplicity through modular construction.
Solution Approach 2:
The patent arranges multiple cores and headers in a nested or space-filling configuration where the second core and second header are positioned to utilize unoccupied regions adjacent to or between the first core and first header. This nesting approach maximizes space utilization and increases heat transfer surface area without significantly increasing device complexity.
3Productivity
If heat exchanger core volume is increased to improve heat transfer capability, then heat transfer efficiency improves, but the orientation and shape are restricted by packaging constraints
Solution Approach 1:
The patent employs flexible tubing or bendable microchannel tubes that can be configured into various shapes (A-shape, M-shape, V-shape, etc.) to adapt to different packaging constraints. This dynamic configurability allows the heat exchanger to achieve high heat transfer capability while accommodating various orientations and spatial arrangements within the heating and cooling system.
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
This configuration enhances heat transfer efficiency by maximizing the heat transfer surface area within a compact volume, accommodating system components and improving system performance by optimizing the use of available space.
Implementation Method 1
a first plurality of fins disposed between adjacent tubes of the first plurality of microchannel tubes
Implementation Method 2
the first plurality of fluid passages are in fluid communication with the first collection volume and the second collection volume
Data Source
AI summary
Disclosed is a microchannel heat exchanger comprising a primary core including a first header and a second header and a secondary core including a first auxiliary header and a second auxiliary header, further comprising a first header interconnect extending between the first header and the first auxiliary header and having a first interconnect fluid passage extending therethrough; and a second header interconnect extending between the second auxiliary header and the second header and having a second interconnect fluid passage extending therethrough.