Mixing And Redistribution Header for Uniform Outlet Air Temperature
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Solution Overview
Problem
Conventional heat exchangers in air conditioning systems suffer from inefficiencies in heat exchange due to temperature differences, leading to non-uniform air temperatures and reduced comfort, often requiring the use of two heat exchangers which increase costs and complexity.
Innovation Solution
A heat exchanger design featuring a mixing and redistribution header with upper and lower cavities, where refrigerant flows through heat exchange tubes, and the cavities are partitioned to ensure balanced distribution and mixing, using jump tubes and strategically placed holes/slots to optimize refrigerant flow and reduce phase separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If two heat exchangers are used to obtain balanced outgoing air temperature, then the temperature uniformity is improved, but the cost and device complexity increase
Solution Approach 1:
The header is segmented into multiple cavities (first cavity, second cavity, third cavity) that are spatially separated and functionally distinct. Each cavity handles specific portions of the refrigerant flow, allowing independent temperature balancing without requiring multiple complete heat exchanger units. This segmentation enables the single heat exchanger to achieve the temperature uniformity that previously required two separate units.
Solution Approach 2:
The fourth cavity acts as an intermediary mixing chamber that receives refrigerant from both the first and third cavities through jump tubes. This intermediate cavity allows thermal mixing and redistribution of refrigerant between different flow paths, enabling temperature balancing without requiring separate heat exchanger units. The intermediary cavity mediates the temperature differences that would otherwise require dual heat exchanger configuration.
2Temperature
If two heat exchangers are used to achieve uniform air temperature, then the comfort level is improved, but the processing difficulty and manufacturing complexity increase
Solution Approach 1:
Multiple cavity functions (inlet, outlet, mixing, redistribution) that would traditionally require separate heat exchanger units are merged into a single integrated header structure. The header combines multiple chambers and flow paths into one manufacturable component, reducing the number of separate parts that need to be fabricated, assembled, and connected, thereby significantly easing manufacturing complexity while maintaining temperature uniformity.
Solution Approach 2:
The jump tubes are nested within the header structure, with the fourth cavity containing the mixing function that redistributes flow to both first and third cavities. This nested arrangement allows complex multi-path flow distribution to be achieved within a single integrated component rather than requiring multiple separate units with external connecting tubes, reducing manufacturing steps and assembly complexity.
3Temperature
If connecting tubes are added at the joint between headers to use two heat exchangers, then the heat exchange area is reduced, but the temperature balancing is improved
Solution Approach 1:
The flow redistribution is achieved by utilizing the vertical dimension within the single header structure through the fourth cavity positioned between the first and third cavities. Jump tubes connect vertically across cavities, enabling three-dimensional flow paths that redistribute refrigerant without requiring external horizontal connecting tubes between separate headers. This dimensional approach maintains heat exchange area while achieving temperature balancing.
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 design achieves a more uniform outgoing air temperature, reducing costs and complexity by eliminating the need for multiple heat exchangers, while maintaining a balanced refrigerant distribution and enhancing heat exchange efficiency.
Implementation Method 1
a fluid entering the heat exchanger first of all flows into a part of the lower cavity of the mixing and redistribution header, then is collected and mixed in the upper cavity of the mixing and redistribution header, and is distributed into another part of the lower cavity
Implementation Method 2
an upper cavity and a lower cavity in communication with each other are disposed in the mixing and redistribution header; a fluid entering the heat exchanger first of all flows into a part of the lower cavity
Implementation Method 3
flat tubes 4, with small channels in the interior thereof, are inserted into the headers 3 by means of slots in the headers 3, and are responsible for heat transfer between a refrigerant and air
Implementation Method 4
When air, driven by a blower, flows past the fins 5 and flat tubes 4, the temperature difference between the air and refrigerant causes heat to be transferred between these two media
Implementation Method 5
Corrugated fins 5 between the flat tubes are responsible for enhancing the heat exchange effect
Implementation Method 6
Corrugated fins 5 between the flat tubes are responsible for enhancing the heat exchange effect
Data Source
AI summary
A heat exchanger including a mixing and redistribution header (20) at one end of the heat exchanger; multiple heat exchange tubes (30) in communication with the mixing and redistribution header (20). An upper cavity (21) and a lower cavity (22) in communication with each other are disposed in the mixing and redistribution header (20); a fluid entering the heat exchanger first of all flows into a part of the lower cavity (22) of the mixing and redistribution header (20), then is collected and mixed in the upper cavity (21) of the mixing and redistribution header (20), and is distributed into another part of the lower cavity (22) and flows out through a heat exchange tube (30) in communication with the lower cavity, a cross-sectional area of the upper cavity (21) being equal to or greater than a cross-sectional area of the lower cavity (22).