Staggered Fin Micro-Channel Heat Exchanger Design
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Solution Overview
Problem
Existing micro-channel heat exchangers face challenges with high fluid flow resistance and poor heat exchange capacity due to suboptimal design, leading to increased pressure loss and limited heat transfer efficiency, especially when dealing with heat exchange between water and a cooling agent.
Innovation Solution
A stacked-plate micro-channel structure with staggered fin units arranged perpendicular to the fluid flow direction, featuring a combination of rectilinear and curvilinear shapes, and spaced fin configurations to enhance turbulence and contact area, reducing fluid pressure loss and increasing heat transfer efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If straight channels with square-shaped or circular-shaped cross-sections are used in micro-channel heat exchangers, then the structure is simple and easy to manufacture, but the fluid pressure loss increases and heat transfer efficiency is limited
Solution Approach 1:
The patent applies curvature principle by transforming the straight channel configuration into a serpentine (sinusoidal) channel structure. The channel centerline follows a sinusoidal curve equation, creating smooth curved paths that reduce flow resistance and pressure loss while maintaining manufacturing feasibility through standard sheet metal forming techniques.
Solution Approach 2:
The patent extends the channel path from a simple linear or circular cross-section into a three-dimensional serpentine configuration. By adding spatial dimensionality through the sinusoidal curve in the flow direction, the channel length and heat exchange area are significantly increased without proportionally increasing pressure loss, as the curved path promotes better fluid mixing and heat transfer.
2Ease of manufacture
If straight channels are used in micro-channel heat exchangers, then the manufacturing process is simple, but the heat exchange area is insufficient and heat transfer capacity is poor
Solution Approach 1:
The serpentine channel configuration with sinusoidal curvature increases the channel length and heat exchange surface area within the same compact footprint. The curved path allows the channel to effectively utilize the available space, providing approximately 50% more heat exchange area compared to straight channels of equivalent outer dimensions.
Solution Approach 2:
By transforming the channel from a straight one-dimensional path into a three-dimensional serpentine structure, the patent maximizes the heat exchange area within the constrained heat exchanger volume. The sinusoidal curve in the flow direction creates multiple undulations that expand the effective heat transfer surface without requiring additional space in the transverse directions.
3Device complexity
If straight channels are used, then the structure is simple, but turbulence and heat transfer enhancement are not considered
Solution Approach 1:
The sinusoidal curved channel structure naturally induces secondary flows and turbulence by creating continuous changes in flow direction. This curvature-induced turbulence enhances heat transfer coefficients and prevents thermal boundary layer stagnation, improving heat transfer reliability without requiring additional complex turbulence-generating devices.
Solution Approach 2:
The three-dimensional serpentine configuration introduces spatial variation in flow velocity and pressure that promotes turbulent mixing. The undulating channel path creates regions of accelerated and decelerated flow that enhance convective heat transfer, making the structure more effective for heat exchange applications while maintaining relative manufacturing simplicity.
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 proposed micro-channel structure increases heat exchange area by 55% compared to straight channels and 4.8%-7.5% over prior streamline designs, while reducing fluid pressure loss by 30.8%-40%, enhancing forced convection heat transfer coefficients and heat exchange capacity with thinner heat-exchange walls.
Implementation Method 1
spaced fin configurations to enhance turbulence and contact area
Implementation Method 2
enhancing forced convection heat transfer coefficients
Implementation Method 3
heat-exchange walls
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present invention discloses a micro-channel structure for a heat exchanger, and an integrated type micro-channel heat exchanger. The micro-channel structure is formed between multiple layers of heat exchange plates (1) arranged in a stacked manner, with a plurality of fin units (2) formed on the heat exchange plate (1), the fin units (2) are arranged uniformly into a plurality of fin unit groups (9) in the direction perpendicular to a flow direction of fluid, and the fin unit groups (9) are arranged in a staggered manner and spaced from one another by a distance in the flow direction of the fluid; a rear end of the fin unit (2) at the upstream side is arranged in an intermediate position between two adjacent fin units (2) at the downstream side; the fin unit (2) comprises at least two fins (21), with the adjacent fins (21) spaced from each other by a distance; and the fluid channels between the adjacent fin units (2) and between the adjacent fins (21) form the micro-channel structure. The integrated type micro-channel heat exchanger comprises multiple layers of heat exchange plates (1) arranged in a stacked manner, with the aforementioned micro-channel structure formed between the heat exchange plates (1).