Micro-Channel Water Chiller Layout for Compact U-Flow Cooling
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Solution Overview
Problem
Conventional water chillers face issues with limited heat transfer efficiency due to restricted surface contact between fluids, leading to bulkiness, packaging problems, pressure drops, and reliability concerns, particularly in vehicular environments.
Innovation Solution
A water chiller design featuring a metal housing with strategically positioned micro-channel tubes and headers that facilitate u-flow and counter-flow configurations, using aluminum panels and header plates to enhance heat exchange efficiency and compactness, while preventing pressure drops and ensuring leak-proof integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the flow path and contact surface area between the second fluid and the micro-channel tubes are increased to improve heat exchange efficiency, then the heat transfer efficiency is improved, but the overall length of the water chiller is increased, rendering it bulky and causing packaging issues
Solution Approach 1:
The patent transitions from a linear one-dimensional flow path to a two-dimensional u-flow configuration by adding water boxes at opposite ends of the housing. The second fluid enters through the second inlet, flows through the housing to the opposite end, and exits through the second outlet, creating a folded flow path that increases contact surface area without proportionally increasing the overall length of the device.
Solution Approach 2:
The micro-channel tubes are nested within the housing structure, with the housing providing both structural support and the flow path for the second fluid. The micro-channel tubes are positioned between the headers and extend along the housing, allowing the first fluid to flow through them while the second fluid flows around them in the housing, maximizing heat exchange surface area within a compact volume.
2Reliability
If the second inlet and second outlet are configured on opposite sides of the housing to enable linear flow, then the flow path length is increased for improved heat exchange, but packaging issues arise due to the configuration
Solution Approach 1:
The patent uses the full three-dimensional space of the housing by implementing u-flow that utilizes the length and width dimensions. The water boxes at opposite ends allow the second fluid to traverse the housing in a folded path, effectively using the available volume more efficiently and reducing the overall packaging volume required compared to a simple linear extension.
3Ease of manufacture
If the housing is formed of plastic material by moulding process, then the manufacturing ease is improved, but the housing cannot withstand high internal pressure and reliability issues occur
Solution Approach 1:
The patent changes the material parameter from plastic to metal (specifically aluminum), fundamentally altering the mechanical properties of the housing. This material substitution enables the housing to withstand high internal pressures from the second fluid while maintaining structural integrity, directly addressing the reliability issue despite increased manufacturing complexity compared to moulding processes.
4Ease of manufacture
If the second inlet and second outlet are formed on the same side to facilitate moulding operation, then the manufacturing ease is improved, but the second fluid flow is obstructed by the micro-channels, causing pressure drop
Solution Approach 1:
The patent resolves the conflict between manufacturing ease and pressure drop by implementing u-flow with water boxes at opposite ends of the housing. This configuration allows the second fluid to flow through the housing in a folded path that bypasses the micro-channel tubes without obstruction, maintaining low pressure drop while still enabling efficient heat exchange. The manufacturing process benefits from the modular design with headers and water boxes that can be assembled separately.
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 significantly improves heat transfer efficiency, reduces bulkiness, and addresses packaging and reliability issues, ensuring effective cooling for vehicular applications by optimizing fluid flow paths and material strength.
Implementation Method 1
heat exchange between the water flowing around the micro-channel tubes 4 and the refrigerant flowing through the micro-channel tubes 4
Implementation Method 2
The micro-channel tubes 4 are separated by turbulators 7 which increase the heat exchange area for the second fluid around the micro-channel tubes 4
Implementation Method 3
The micro-channel tubes 4 are separated by turbulators 7 which increase the heat exchange area for the second fluid around the micro-channel tubes 4
Data Source
Figure 1
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Figure 3
AI summary
A water chiller (100) includes a housing (10) and micro-channel tubes (20). The housing (10) includes first panel (10a), second panel (10b) and spaced apart header plates (10c) formed with openings (12c). The micro-channel tubes (20) received in the openings (12c) on the opposite header plates (10c) define fluid communication between end manifolds (30). At least one of the end manifolds (30) includes distribution and collection columns (32a) and (32b) respectively for distribution and collection of a first fluid with respect to the micro-channel tubes (20). At least one of first panel (10a) and second panel (10b) is configured with an inlet and an outlet on same side. The housing (100) is formed of aluminium and at least one of the first panel (1 0a) and the second panel (10b) is formed with water boxes (12a) to configure u-flow of the second fluid inside the housing (10).