Plastic Coil Heat Exchanger With Conductive Cell Structure
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Solution Overview
Problem
Current thermal energy collection and air conditioning systems face challenges such as high costs, CO2 emissions, complex installation, and limited durability due to the use of materials like silicon carbide and metal tube coils, which hinder widespread adoption and energy efficiency, especially in buildings and transport sectors.
Innovation Solution
A heat exchanger with a coil tube made of low-cost, high-strength thermoformable plastic housed within a structure of periodic cells with high thermal conductivity, enveloped by a binder mass containing high thermal conductivity aggregates, enhancing radial heat flow and reducing material usage and weight, while maintaining efficient heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If silicon carbide and metal tube coils are used for thermal energy collection and air conditioning, then heat transfer efficiency is improved, but cost and CO2 emissions increase
Solution Approach 1:
The patent changes the material parameters from traditional silicon carbide and metal to plastic materials with modified thermal properties. The coil tube is made of plastic with thermal conductivity between 0.2-0.5 W/mK, and the support structure uses plastic with thermal conductivity between 0.1-0.3 W/mK, significantly reducing material cost and embedded CO2 while maintaining functional performance through optimized geometry
Solution Approach 2:
The patent employs composite plastic structures combining different plastic materials with varying thermal conductivities in specific zones. The coil tube uses plastic with higher thermal conductivity (0.2-0.5 W/mK) for heat transfer, while the support structure uses plastic with lower thermal conductivity (0.1-0.3 W/mK) for insulation, creating an optimized composite system that reduces overall energy loss and material cost
2Loss of energy
If metal tube coils are used for heat transfer, then heat transfer capability is improved, but outdoor durability decreases due to freezing
Solution Approach 1:
The patent fundamentally changes the material parameter from metal to plastic, which eliminates the freezing vulnerability of metal tube coils. The plastic material with thermal conductivity between 0.2-0.5 W/mK maintains adequate heat transfer capability while providing inherent resistance to freezing, thereby improving outdoor durability and reliability in cold environments
3Loss of energy
If welding and metal stamping are used to create fins, then heat transfer surface is increased, but manufacturing cost increases
Solution Approach 1:
The patent replaces traditional rigid metal fins created by welding and stamping with thin plastic film structures that are molded as integral parts of the coil tube. These plastic films provide adequate heat transfer surface area while eliminating expensive joining operations, significantly reducing manufacturing cost and simplifying production
Solution Approach 2:
The patent merges the fin structure with the coil tube by molding them as a single integrated plastic component. The thin plastic films extend from the coil tube to create heat transfer surfaces, eliminating the need for separate fin manufacturing and assembly operations, thereby reducing manufacturing complexity and cost
4Loss of energy
If high temperature differentials are used between heat transfer fluid and air, then heat transfer is improved, but low enthalpy air conditioning is prevented
Solution Approach 1:
The patent uses composite plastic structures with optimized thermal conductivity distribution to enhance heat transfer efficiency at lower temperature differentials. The coil tube uses plastic with higher thermal conductivity (0.2-0.5 W/mK) to maximize heat transfer from the fluid, while the support structure uses insulating plastic (0.1-0.3 W/mK) to maintain temperature gradients, enabling effective heat transfer without requiring high temperature differentials
Solution Approach 2:
The patent employs curved and optimized geometries in the plastic coil tube and support structure to enhance heat transfer surface area and improve thermal contact. The molded plastic structures are designed with optimal curvature and thickness profiles that maximize heat transfer efficiency at lower temperature differentials, enabling low enthalpy operation
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 provides a cost-effective, robust, and efficient heat transfer system with reduced CO2 footprint, capable of achieving low enthalpy air conditioning with high efficiency, suitable for various applications including buildings, transport, and data centers, by increasing the contact area and reducing temperature gradients.
Implementation Method 1
a binder mass (3) enveloping the coil tube (1), and said binder mass (3) includes aggregates with high thermal conductivity
Implementation Method 2
at least one coil tube (1) for the internal circulation of a heat transfer fluid (2)... periodic cells (4) for the circulation of air (5) through their interior
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
Heat exchanger, having at least one coil tube (1) for a heat transfer fluid to circulate inside it, the coil tube (1) being housed inside a structure of periodic cells (4) for the internal circulation of air (5), which walls have a thermal conductivity greater than 100 W/mK. The exchanger also has enclosing means housing the periodic cell structure (4) inside, forming a sandwich-like configuration. The coil tube (1) is made of plastic, and the heat exchanger has a binder mass (3) enveloping the coil tube (1), such that the binder mass (3) has an aggregate thermal conductivity greater than 25 W/mK so that the composite material has a thermal conductivity greater than 4 W/mK.