Stacked Heat Exchanger With Inter-Tube Thermal Isolation
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Solution Overview
Problem
Conventional heat exchangers with multiple flat tubes connected between header collecting pipes face inefficiencies due to heat loss from adjacent tubes, leading to reduced condenser performance and overall heat exchange efficiency, especially when stacked.
Innovation Solution
The heat exchanger design includes a configuration where flat tubes are arranged vertically with distinct upper and lower heat exchange regions, minimizing the number of adjacent parts with different refrigerant temperatures, and incorporating a heat transfer reduction structure between these regions to reduce heat exchange between adjacent tubes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of flat tubes is increased to increase the amount of circulating refrigerant, then the refrigerant circulation capacity is improved, but the length of the header collecting pipe increases and sufficient condenser performance cannot be realized
Solution Approach 1:
The heat exchanger is divided into multiple heat exchange units, each with its own header collecting pipes and flat tubes. This segmentation allows refrigerant to be distributed to multiple units simultaneously, increasing the total refrigerant circulation capacity without requiring a single excessively long header pipe. Each unit operates semi-independently, maintaining efficient heat exchange performance.
Solution Approach 2:
Multiple heat exchange units are arranged in a stacked configuration along the vertical direction rather than extending horizontally. This dimensional change allows the system to accommodate more flat tubes and increase refrigerant circulation capacity while keeping the horizontal footprint and header pipe length manageable through vertical stacking.
2Quantity of substance
If heat exchangers are stacked to increase the amount of circulating refrigerant, then the refrigerant circulation capacity is improved, but heat transfer occurs between adjacent flat tubes with different refrigerant temperatures causing heat loss
Solution Approach 1:
A heat transfer reduction structure is introduced as an intermediary element between adjacent flat tubes of different heat exchange units. This structure acts as a thermal barrier that prevents direct heat transfer between refrigerant streams with different temperatures, thereby eliminating the heat loss that would otherwise occur in stacked configurations.
Solution Approach 2:
The heat transfer reduction structure is applied selectively at specific locations where adjacent flat tubes with different refrigerant temperatures would otherwise be in direct contact. This localized application of thermal insulation precisely addresses the heat loss problem at the critical interfaces between units without affecting the overall heat exchange efficiency.
3Device complexity
If flat tubes are positioned lower to accommodate liquid refrigerant accumulation, then the condenser structure is simplified, but the flow rate of gas refrigerant into the flat tube decreases and sufficient condenser performance cannot be realized
Solution Approach 1:
The condenser function is distributed across multiple heat exchange units stacked vertically. Each unit contains both liquid and gas refrigerant processing capabilities through its own flat tubes and header collecting pipes. This segmentation allows liquid refrigerant to accumulate in lower units while gas refrigerant flows efficiently through upper units, maintaining high flow rates and condenser performance without structural simplification compromises.
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 minimizes heat loss and enhances the heat exchange efficiency by reducing the number of adjacent parts with different refrigerant temperatures and using a heat transfer reduction structure to block heat transfer between specific tubes, thereby improving the performance of the heat exchanger.
Implementation Method 1
incorporating a heat transfer reduction structure between these regions to reduce heat exchange between adjacent tubes
Implementation Method 2
exchanges heat between refrigerant flowing inside the flat tube and air flowing outside the flat tube
Implementation Method 3
heat exchange between refrigerant and air
Data Source
AI summary
A first header collecting pipe is divided into an upper space corresponding to an upper heat exchange region and a lower space corresponding to a lower heat exchange region. The lower space is divided into a plurality of communication spaces corresponding respectively to auxiliary heat exchange parts of the lower heat exchange region. A second header collecting pipe is divided into a communication space corresponding to both of a first main heat exchange part and the third auxiliary heat exchange part, and into communication spaces corresponding respectively to other main heat exchange parts and the other auxiliary heat exchange parts. Each of pairs of communication space and communication space is connected to an associated one of communication pipes.