Microchannel Heat Exchanger Non-Circular Tubes

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Solution Overview

Problem

Shell and tube heat exchangers are costly and inefficient, contributing to increased size and material usage, particularly in HVAC and refrigeration systems, due to their limited ability to meet rising energy efficiency demands and reduce carbon emissions.

Innovation Solution

A microchannel heat exchanger design with non-circular tubular bodies and microchannels for enhanced heat transfer, allowing for compact configurations, reduced refrigerant charge, and improved structural rigidity, using materials like copper, aluminum, or plastic with applied coatings and surface features to promote condensation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional shell and tube heat exchanger design is used, then structural strength is maintained, but heat transfer efficiency is insufficient and device size is large

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidheat exchanger size

Core Design Contradiction:

ProductivityVSVolume of stationary object

Solution Approach 1:

The patent changes the geometric parameters of the heat exchanger by using non-circular cross-sections (oval, rectangular, triangular) instead of traditional circular tubes. This parameter change increases the surface area to volume ratio and improves heat transfer efficiency while reducing the overall device size. The microchannel configuration further optimizes these parameters for enhanced thermal performance.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent transitions from two-dimensional heat transfer surfaces to three-dimensional non-circular cross-sections that utilize space more effectively. The microchannel design adds another dimension of complexity, creating multiple heat transfer paths within a compact volume, thereby improving heat transfer efficiency without proportionally increasing size.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Strength

If traditional shell and tube heat exchanger design is used, then structural strength is maintained, but material usage is excessive and cost is high

Engineering Contradiction:

Improvestructural strengthVSAvoidmaterial usage

Core Design Contradiction:

StrengthVSLoss of substance

Solution Approach 1:

The patent changes the cross-sectional geometry parameters to non-circular shapes that provide equivalent or superior structural strength with reduced material consumption. The microchannel design allows for thinner walls and less material while maintaining structural integrity through optimized geometric parameters and support structures.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite construction techniques where different materials are used for the shell, tubes, and microchannel structures. This allows optimization of each component for its specific function - structural support versus heat transfer - thereby reducing overall material usage while maintaining strength where required.

Inventive Principle:

Principle #40Composite materials

3Productivity

If microchannel design with non-circular cross-section is used, then heat transfer efficiency is enhanced, but manufacturing complexity increases

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidmanufacturing complexity

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent divides the heat exchanger into modular sections with standardized non-circular tube configurations. This segmentation allows the complex microchannel design to be manufactured using repeatable processes, reducing overall manufacturing complexity despite the advanced geometry. Each module can be produced independently and assembled into the complete heat exchanger.

Inventive Principle:

Principle #1Segmentation

4Use of energy by moving object

If refrigerant amount is reduced to meet efficiency demands, then energy efficiency improves, but heat transfer capacity may be insufficient

Engineering Contradiction:

Improveenergy efficiencyVSAvoidheat transfer capacity

Core Design Contradiction:

Use of energy by moving objectVSProductivity

Solution Approach 1:

The patent changes the physical parameters of the heat transfer system through non-circular cross-sections and microchannel designs that dramatically increase surface area. This allows sufficient heat transfer capacity to be achieved with reduced refrigerant charge, as the enhanced surface area compensates for the lower refrigerant volume by improving heat transfer coefficients and efficiency.

Inventive Principle:

Principle #35Parameter changes

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 microchannel heat exchanger design enhances system efficiency, reduces footprint and weight, and minimizes material usage while improving heat transfer performance and structural integrity.

Implementation Method 1

heat transfer occurs between the first and second fluids

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS9777964B2Micro-port shell and tube heat exchanger

Publication Date: 2017.10.03 CARRIER CORP

AI summary

A heat exchanger adapted to transmit a first fluid through an interior, having a tubular body receptive of a second fluid, whereby heat transfer occurs between the fluids is provided, the tubular body extending longitudinally through the interior, having a non-circular cross-section, and being formed to define microchannels extending longitudinally along the tubular body through which the second fluid is transmitted.