Micro-Channel Condenser Layout for Low-Charge Propane Ice Makers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing ice making machines using HFC refrigerants are environmentally unfriendly and pose safety risks due to flammability issues when using hydrocarbon (HC) refrigerants like propane, which are more environmentally friendly but require careful management to avoid explosions or fires, especially in commercial settings where consumers are present.
Innovation Solution
Designing an ice making machine with a low volume condenser for HC refrigerants, specifically propane, to minimize the risk of flammability, using a micro-channel condenser with reduced refrigerant volume and internal components to prevent sparking, and optimizing the system for energy efficiency to match conventional machines' output while reducing energy usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If hydrocarbon refrigerant (propane) is used to replace HFC refrigerant, then environmental friendliness and energy efficiency are improved, but flammability risk and safety hazards worsen
Solution Approach 1:
The patent extracts the harmful flammable hydrocarbon refrigerant from the system and replaces it with non-flammable HFC refrigerant, thereby eliminating the fire hazard while maintaining the cooling function. This directly addresses the safety concern by removing the dangerous substance rather than trying to manage its risks.
Solution Approach 2:
The patent introduces a refrigerant management system including sensors, control valves, and monitoring devices that act as intermediaries to detect and control refrigerant levels and conditions. This intermediary system provides early warning and automatic response to prevent flammable conditions from developing, bridging the gap between using efficient HC refrigerants and ensuring safety.
2Productivity
If conventional condenser design is used with HC refrigerant, then refrigeration capacity is maintained, but refrigerant volume and flammability risk increase
Solution Approach 1:
The patent changes the physical parameters of the condenser including reducing tube diameter, increasing tube density, optimizing fin spacing, and adjusting overall condenser dimensions. These parameter changes enable the condenser to maintain the same heat rejection capacity while accommodating less refrigerant volume, thereby reducing the quantity of flammable HC refrigerant in the system.
Solution Approach 2:
The patent transitions from a conventional two-dimensional coil layout to a three-dimensional micro-channel plate structure. This dimensional change allows for much higher heat transfer efficiency per unit volume, enabling compact condenser design that achieves the required refrigeration capacity with significantly reduced refrigerant charge.
3Object-generated harmful factors
If micro-channel condenser with reduced volume is used, then flammability risk is minimized, but manufacturing complexity and design difficulty increase
Solution Approach 1:
The patent segments the condenser into standardized micro-channel plates with repeating patterns of channels and fins. Each plate is a modular unit that can be manufactured independently using precision stamping or extrusion processes, then assembled into the complete condenser. This segmentation simplifies manufacturing despite the advanced geometry required for low refrigerant volume.
Solution Approach 2:
The patent establishes specific parameter ranges for the micro-channel geometry including channel width (0.5-2mm), channel spacing, fin thickness, and plate dimensions. By defining these parameters within optimized ranges, the design achieves the required performance while using conventional manufacturing capabilities, thereby managing design complexity through parameter standardization.
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 allows for safe and efficient use of hydrocarbon refrigerants, minimizing the risk of explosions and fires, while maintaining or exceeding the ice production capacity of conventional machines with significantly reduced energy consumption, using less than 90% of the energy of standard machines.
Implementation Method 1
a condenser for condensing a compressed hydrocarbon coolant/refrigerant
Implementation Method 2
the condenser having a total internal volume of between about 100 ml to about 250 ml
Implementation Method 3
micro channels disposed between said inlet port and said outlet port and between said first and second header
Data Source
AI summary
An ice making machine using hydrocarbon (HC), and particularly propane, as the refrigerant is disclosed. The ice making machine has components which have been modified in size, type and operation to accommodate the use of HCs, and particularly propane, in the ice making machine refrigerant system. Also disclosed is a low volume condenser especially designed for HCs, and in particular propane, to minimize the volume of flammable/explosive HC in the ice making machine refrigerant system.