Two-Pass Heat Exchanger Bypass Layout for Lower Pressure Drop
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Solution Overview
Problem
Existing heat exchangers face limitations in achieving improved thermal performance and reduced pressure drop without increasing cost or complexity, particularly in cooling heat-generating substrates in vehicles where temperature differentials across the heat exchanger impact performance.
Innovation Solution
A two-pass heat exchanger design with stacked fluid flow passages, manifold openings, and bypass openings that allow heat transfer fluid to bypass portions of the passages, utilizing corrugated fin sheets and structural elements to enhance heat transfer and turbulence, while minimizing pressure drop.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If cooling fins or turbulizers are added to coolant flow passages to improve heat transfer performance, then heat transfer performance is improved, but pressure drop increases
Solution Approach 1:
A bypass passage is introduced as an intermediary flow path that allows coolant to circumvent regions with high flow resistance (such as areas with cooling fins or turbulizers). This mediator pathway reduces the overall pressure drop while maintaining heat transfer performance in the primary cooling zones.
Solution Approach 2:
The system changes the flow distribution parameters by providing multiple parallel pathways (primary cooling passages and bypass passages). This allows dynamic adjustment of flow rates through different regions, enabling optimized heat transfer performance while controlling pressure drop across the heat exchanger.
2Device complexity
If a single-pass heat exchanger design is used, then the structure is simpler, but temperature differential across heat-generating substrates is larger
Solution Approach 1:
The heat exchanger is segmented into multiple flow passages (first and second fluid flow passages) arranged in stacked relation. This segmentation allows the coolant to service multiple heat-generating substrates in series, reducing the temperature differential between substrates while maintaining a relatively simple overall structure.
Solution Approach 2:
The invention transitions from a single-planar passage design to a three-dimensional stacked configuration with multiple fluid flow passages arranged in the thickness dimension. This dimensional change enables more efficient thermal servicing of substrates while maintaining structural simplicity.
3Power
If multiple stacked fluid flow passages are used to reduce temperature differential, then thermal performance is improved, but device complexity increases
Solution Approach 1:
Multiple fluid flow passages are merged into a single integrated heat exchanger structure with shared plate walls and manifold openings. This combining approach achieves improved thermal performance through multiple passages while avoiding the complexity of separate independent cooling channels.
Solution Approach 2:
The intermediate plate wall serves multiple functions: it forms the boundary between stacked fluid flow passages, provides structural support, and contains manifold openings for flow distribution. This multi-functionality reduces the number of separate components needed, thereby reducing overall device 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
The design achieves improved thermal performance and reduced temperature differentials across heat-generating substrates, enhancing the overall efficiency and durability of the heat exchanger while maintaining a balanced pressure drop.
Implementation Method 1
heat generated by the heat-generating substrates is transferred to the heat transfer fluid as it is circulated from the inlet port to the outlet port
Implementation Method 2
heat transfer fluid makes two passes through the heat exchanger
Implementation Method 3
one or more channel elements in at least one of the cooling zones comprises a corrugated fin sheet which is in contact with the intermediate plate wall and one of the first and second outer plate walls
Data Source
AI summary
A two-pass heat exchanger with calibrated bypass is disclosed for cooling heat-generating substrates and/or for heating a heat transfer fluid. The heat exchanger has first and second outer plate walls and an intermediate plate wall located between and spaced from the outer plate walls in the thickness dimension of the heat exchanger, and with inlet and outlet ports at the same end. An input flow passage is defined between the first outer plate wall and the intermediate plate wall, and a return flow passage is defined between the second outer plate wall and the intermediate plate wall. The first and second fluid flow passages are in a U-flow, stacked arrangement. At least one bypass opening extends through the intermediate plate wall between the input and return flow passages, and configured to permit a portion of the heat transfer fluid to bypass portions of the input and return flow passages.