Multi-Pass Heat Exchanger with Adjustable Flow Paths for Variable Load
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional heat exchangers face inefficiencies and mechanical failures due to inability to handle variable loads and refrigerant charge levels, leading to improper liquid and gas distribution, which results in suboptimal performance and potential mechanical issues.
Innovation Solution
An adjustable multi-pass heat exchanger with adjustable valves and manifolds that allow for customization of flow paths and fluid flow direction, enabling operation on a constant refrigerant charge and separating gas from liquid, thus accommodating variable loads and optimizing system efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If heat exchangers are designed for high or average load, then they can handle maximum capacity, but they perform inefficiently when operating outside design conditions
Solution Approach 1:
The patent implements adjustable flow distributors and bypass valves that dynamically reconfigure the heat exchanger circuitry based on operating conditions. This allows the system to transition between different operational modes (single-pass, multi-pass, series, parallel) to maintain efficiency across variable loads, directly resolving the contradiction between fixed design capacity and adaptive performance
2Productivity
If refrigerant charge is increased to handle high load, then maximum cooling capacity is achieved, but excess liquid collects in low-load conditions causing mechanical failures
Solution Approach 1:
The adjustable flow distributors and bypass mechanisms dynamically control refrigerant distribution to matches actual system demand. This prevents both insufficient cooling at high load and dangerous liquid accumulation at low load, maintaining reliability across the full operating range while using a constant refrigerant charge
Solution Approach 2:
The system uses sensors to monitor refrigerant flow, pressure, and temperature conditions, then adjusts the flow distributors and bypass valves accordingly. This closed-loop control ensures optimal refrigerant distribution under varying conditions, preventing liquid slugging and mechanical failures
3Ease of manufacture
If heat exchanger circuitry is fixed for a given load, then manufacturing is simple, but the system cannot handle variable loads efficiently
Solution Approach 1:
The heat exchanger is divided into multiple independent circuit paths with individual flow distributors and control valves. This modular segmentation allows the system to maintain a relatively simple base manufacturing process while adding flexibility through discrete control elements that can be adjusted to create different operational configurations
Solution Approach 2:
The adjustable flow distributors and bypass valves enable the same heat exchanger hardware to perform multiple functions - operating as single-pass or multi-pass, series or parallel configurations - without requiring different physical components, thus achieving versatility without proportionally increasing manufacturing complexity
4Quantity of substance
If insufficient liquid collects in manifolds, then gas accumulates in the system, but if excess liquid collects, then mechanical failures occur
Solution Approach 1:
The adjustable flow distributors dynamically balance refrigerant distribution to ensure proper liquid-gas separation in the manifolds under all operating conditions. This prevents both gas accumulation and liquid slugging by continuously adapting flow patterns to match system demands, maintaining reliability
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 adjustable heat exchanger enhances efficiency by allowing customization of flow paths and fluid flow, preventing mechanical failures and optimizing performance across varying loads and refrigerant levels, ensuring optimal liquid and gas distribution.
Implementation Method 1
a first plurality of channels connecting the first and second manifolds and operable to allow airflow around the exterior of each channel
Data Source
AI summary
An air conditioner includes a heat exchanger having one or more flow paths. At least one of the flow paths is associated with more than one pass and/or fluid flow through the flow path is restricted. A setting of the beat exchanger includes associations between flow path(s) and/or pass(es). A setting for the heat exchanger is determined and the heat exchanger is allowed to operate in the determined setting.