U-Shaped Evaporator Separator for Low-Refrigerant Vapor Separation

Solution Overview

Problem

Traditional evaporator separators are bulky, heavy, and costly, with a large refrigerant charge that poses safety risks and occupy significant space, while existing designs struggle with efficient separation and fluid pressure management in refrigeration systems.

Innovation Solution

A U-shaped pipe separator comprising two parallel pipes interconnected by a pipe portion, arranged essentially horizontally, which reduces weight, size, and material costs while enhancing separation efficiency and safety by using standard components and minimizing refrigerant charge.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional separators are used, then separation function is provided, but weight and occupied space increase significantly

Engineering Contradiction:

Improveseparation functionVSAvoidseparator weight

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The separator is divided into multiple vertical channels within the plate heat exchanger structure, allowing separation functionality to be distributed across several parallel paths rather than requiring a single large separator vessel

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The separator function is merged with the plate heat exchanger structure itself, combining two separate components (separator and heat exchanger) into a single integrated unit, eliminating the need for a standalone separator vessel

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If traditional separators are used, then separation function is provided, but occupied space increases significantly

Engineering Contradiction:

Improveseparation functionVSAvoidseparator area

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The separator is divided into multiple vertical channels within the plate heat exchanger structure, allowing separation functionality to be distributed across several parallel paths rather than requiring a single large separator vessel

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The separator function is merged with the plate heat exchanger structure itself, combining two separate components (separator and heat exchanger) into a single integrated unit, eliminating the need for a standalone separator vessel

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If traditional separators are used, then separation function is provided, but material costs increase

Engineering Contradiction:

Improveseparation functionVSAvoidmaterial cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The separator function is merged with the plate heat exchanger structure itself, combining two separate components (separator and heat exchanger) into a single integrated unit, eliminating the need for a standalone separator vessel

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The separator uses the same plate material and manufacturing process as the heat exchanger plates, allowing for homogeneous construction from standard plate heat exchanger materials rather than requiring specialized separator materials

Inventive Principle:

Principle #33Homogeneity

4Reliability

If large refrigerant charge is used in separator, then separation capacity is improved, but safety risks increase

Engineering Contradiction:

Improveseparation capacityVSAvoidsafety risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The separator is divided into multiple vertical channels within the plate heat exchanger structure, allowing separation functionality to be distributed across several parallel paths rather than requiring a single large separator vessel

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The separator function is merged with the plate heat exchanger structure itself, combining two separate components (separator and heat exchanger) into a single integrated unit, eliminating the need for a standalone separator vessel

Inventive Principle:

Principle #5Merging (Combining)

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 compact design improves separation efficiency, reduces weight and material costs, and enhances safety by reducing the refrigerant charge, making the system more space-efficient and cost-effective while maintaining cooling efficiency at part loads.

Implementation Method 1

The separation of the vapour and the liquid is obtained by gravitational forces

Methodology Applied

Scientific EffectGravitational separation: Gravitation

Implementation Method 2

the heavier liquid droplets to settle

Methodology Applied

Scientific EffectDensity gradient separation: Density Gradient

Implementation Method 3

Before the refrigerant enters the evaporator the pressure of the refrigerant has to be brought down to the evaporating pressure and temperature by expanding the refrigerant. In this process a part of the refrigerant vaporises.

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 4

The two-phase mixture that leaves the expansion valve separates into vapour and liquid in a separator

Methodology Applied

Scientific EffectPhase change: Phase Change

Data Source

PatentUS10036583B2Liquid separator for an evaporator system

Publication Date: 2018.07.31 ALFA LAVAL CORP AB

AI summary

Liquid separator (2), designed as a U-shaped pipe (5) and arranged essentially horizontally, for a plate heat exchanger evaporator (1) system for separation of liquid droplets from vapor transported from the evaporator to the separator.