Pulsating Heat Pipe Exchanger With Barrier-Separated Air Streams
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Solution Overview
Problem
Existing heat exchangers for electronic enclosures face challenges in efficiently cooling contaminated environments while maintaining corrosion resistance and compactness, especially when ambient temperatures are lower than internal temperatures, and they often suffer from galvanic corrosion and increased complexity.
Innovation Solution
A compact air-to-air heat exchanger with a pulsating heat pipe using a single metallic material, such as aluminum, separated by a barrier to prevent contamination, featuring a serpentine configuration and capillary channels filled with a two-phase refrigerant, which enhances heat transfer efficiency and corrosion resistance without the need for wicking structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a traditional heat exchanger uses multiple metallic materials (e.g., copper and aluminum) to enhance heat transfer efficiency, then heat transfer performance is improved, but galvanic corrosion occurs due to contact between dissimilar metals
Solution Approach 1:
The heat exchanger uses a single metallic material (aluminum) for both the evaporator and condenser sections, eliminating galvanic corrosion by removing the dissimilar metal contact. The patent states: 'The heat exchanger according to the invention comprises a condenser side and an evaporator side wherein the condenser side and the evaporator side are separated from each other by a barrier... The heat exchanging element is a pulsating heat pipe... The metallic material is preferably aluminum'
2Reliability
If the condenser side and evaporator side are completely separated by a barrier to prevent contamination ingress, then corrosion resistance and reliability are improved, but device complexity increases
Solution Approach 1:
The barrier is integrated as an inner wall of the heat exchanger casing rather than being a separate component. The patent states: 'The barrier can advantageously be formed by an inner wall of a casing of the heat exchanger', which combines the separation function with the structural housing, reducing overall complexity
Solution Approach 2:
The barrier serves multiple functions: it separates the condenser and evaporator air streams, prevents contamination ingress, and provides structural support as part of the casing. This multi-functionality reduces the need for additional separate components
3Volume of moving object
If a compact heat exchanger design is used to reduce volume, then space efficiency is improved, but manufacturing precision requirements increase
Solution Approach 1:
The pulsating heat pipe uses phase change parameters (liquid-vapor transitions) to achieve high heat transfer coefficients in a compact form. The patent states: 'The heat exchanging element is a pulsating heat pipe... channels which are filled with a two-phase refrigerant, in particular R134a or R407c', allowing compact design without excessive precision requirements
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 more efficient cooling capacity with reduced volume and cost, achieving up to 62% volume reduction per unit of heat transfer while maintaining corrosion resistance and operational effectiveness in various orientations.
Implementation Method 1
channels which are filled with a two-phase refrigerant
Implementation Method 2
The heat exchanging element is a pulsating heat pipe
Implementation Method 3
the condenser side and the evaporator side are separated from each other by a barrier... the barrier is configured as an air side barrier for completely separating the first air stream on the evaporator side and the second air stream on the condenser side
Implementation Method 4
A compact air-to-air heat exchanger with a pulsating heat pipe
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
In order to reduce the dimensions and costs of a heat exchanger (10), while at the same time increasing its heat effectiveness, it is suggested to configure the heat exchanger (10) such that a condenser side (15) and an evaporator side (12) of the heat exchanger (10) are separated from each other by a barrier (18).