Systems and Methods for Interlaced Microchannel Heat Exchanger Systems with Multiple Compressors of Different Sizes
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Solution Overview
Problem
Existing air systems with multiple compressors are limited in efficiency due to symmetrical heat exchanger designs, restricting them to compressors of the same size, which hinders their ability to adjust operation based on demand.
Innovation Solution
Implementing interlaced microchannel heat exchangers with refrigerant circuits that accommodate compressors of different sizes, allowing selective operation of refrigerant circuits and compressors to match varying demand levels, enhancing efficiency and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If symmetrical microchannel heat exchanger design is used, then manufacturing simplicity is maintained, but the system is limited to compressors of the same size reducing operational flexibility
Solution Approach 1:
The patent applies asymmetry by designing interlaced microchannel heat exchangers with different numbers of microchannel rows for each refrigerant circuit. Specifically, the first microchannel heat exchanger has a first number of microchannel rows while the second has a second number of microchannel rows, allowing the system to accommodate compressors of different sizes and capacities. This asymmetric configuration enables operational flexibility where compressors of varying sizes can be selectively operated based on demand, directly resolving the contradiction between adaptability and design complexity.
Solution Approach 2:
The patent segments the heat exchanger into multiple independent refrigerant circuits, each with its own compressor and microchannel rows. This segmentation allows each circuit to be independently controlled and sized according to specific compressor requirements. The interlaced microchannel design further segments the heat transfer paths, enabling precise matching of heat exchanger capacity to compressor output for each circuit, thereby achieving operational flexibility without requiring a completely new integrated design.
2Use of energy by moving object
If multiple compressors of different sizes are used, then part-load and full-load efficiency are improved, but heat exchanger design complexity increases
Solution Approach 1:
The patent applies local quality by configuring different sections of the interlaced microchannel heat exchanger with different numbers of microchannel rows corresponding to different refrigerant circuits. Each local section of the heat exchanger is optimized for its specific compressor's thermal requirements. This allows the system to achieve high energy efficiency at both part-load and full-load conditions by activating only the necessary compressors and their corresponding optimized heat exchanger sections, while avoiding the need for a completely complex redesigned heat exchanger structure.
3Ease of operation
If symmetrical heat exchanger design is used, then manufacturing is simpler, but the system cannot selectively operate compressors based on demand
Solution Approach 1:
The patent resolves this contradiction by implementing asymmetry in the microchannel row configuration while maintaining manufacturing feasibility. The interlaced microchannel heat exchangers are designed with different numbers of rows for different refrigerant circuits, enabling selective compressor operation based on demand. The asymmetric design is integrated into the manufacturing process rather than being an afterthought, allowing the system to achieve operational flexibility without prohibitive manufacturing complexity.
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
Achieves full-load and part-load efficiency by selectively operating compressors of varying sizes, improving energy savings and operational flexibility.
Implementation Method 1
indoor heat exchanger (e.g., evaporator) and a single outdoor heat exchanger (e.g., condenser)... Each of the refrigerant circuits may flow through a single indoor heat exchanger (e.g., evaporator) and a single outdoor heat exchanger (e.g., condenser)
Implementation Method 2
indoor heat exchanger (e.g., evaporator)... Each refrigerant circuit may be configured to pass through an indoor heat exchanger (e.g., evaporator)
Implementation Method 3
Each refrigerant circuit may include a compressor and the compressors may be different sizes... Each refrigerant circuit may include a compressor and the compressors may be different sizes
Data Source
AI summary
Systems and methods for multi-circuit air systems have been developed that include a plurality of fluidly separated refrigerant circuits. Each of the refrigerant circuits may flow through a single indoor heat exchanger (e.g., evaporator) and a single outdoor heat exchanger (e.g., condenser). The refrigerant may be selectively and independently flowed through each individual refrigerant circuit. Each refrigerant circuit may include a compressor, which may have different sizes. The heat outdoor and/or indoor heat exchangers may be interlaced microchannel heat exchangers designed to accommodate different refrigerant charge quantities in the different refrigerant circuits. The interlaced heat changers may include alternating rows connected to the different refrigerant circuits to efficiently exchange thermal energy across the entire heat exchanger.