Water Charge Air-Cooler Panel Apertures Deflectors
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Solution Overview
Problem
Conventional Water Charge Air-Coolers suffer from inefficient heat exchange and reduced performance due to the formation of dead zones in the heat exchanger core, caused by non-uniform coolant distribution and the tendency of coolant to follow the shortest path, which also reduces the number of heat exchange elements that can be accommodated without intruding into the housing.
Innovation Solution
The design incorporates panels with apertures and deflectors that align with the openings of the waterboxes, ensuring uniform coolant distribution across the heat exchange elements by guiding the coolant flow to paths other than the shortest path, preventing dead zone formation without occupying additional space within the housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If coolant is allowed to flow freely between the first opening and the second opening, then the coolant flow rate is high, but the coolant follows the shortest path and creates dead zones in the heat exchanger core
Solution Approach 1:
The patent segments the coolant flow path by introducing multiple flow distribution plates with varying aperture patterns. These plates divide the single shortest path into multiple distributed paths, forcing coolant to flow through different regions of the heat exchanger core. The segmentation of flow paths ensures uniform coolant distribution across all heat exchange elements while maintaining high overall flow rate.
Solution Approach 2:
The flow distribution plates are designed with non-uniform aperture distributions where different regions have different aperture sizes and densities. This local quality variation directs coolant preferentially to regions that need more cooling while reducing flow to already-cooled areas, eliminating dead zones and ensuring optimal heat exchange efficiency throughout the entire core.
2Reliability
If flow distribution arrangements are added to uniform coolant distribution, then dead zones are prevented, but the interior space of the housing is occupied and the number of heat exchange elements is reduced
Solution Approach 1:
The flow distribution plates are merged with the existing housing structure and heat exchange element supports. The plates serve dual functions: they distribute coolant uniformly while also acting as structural supports for the heat exchange elements. This integration eliminates the need for separate flow distribution components, maximizing the use of available housing space.
Solution Approach 2:
The flow distribution plates are nested within the existing housing and heat exchange element assembly. The plates are positioned in the gaps and spaces already present in the heat exchanger structure, utilizing otherwise wasted space. This nesting approach allows flow distribution functionality to be added without increasing the overall housing volume or reducing the number of heat exchange elements.
3Reliability
If the heat exchanger configuration is fixed to accommodate flow distribution arrangements, then coolant distribution is improved, but the adaptability to different orientations and layouts is reduced
Solution Approach 1:
The flow distribution plates are designed with adjustable and reconfigurable features that allow them to adapt to different heat exchanger orientations and layouts. The aperture patterns and plate positions can be modified based on the specific application requirements, enabling the same basic design to serve multiple configurations while maintaining uniform coolant distribution.
Solution Approach 2:
The flow distribution plate design incorporates universal features that make it applicable to various heat exchanger types, orientations, and layouts. The plates can be configured to work with different heat exchange element arrangements and housing geometries, providing a single versatile solution that maintains reliable coolant distribution across diverse applications.
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 configuration enhances heat transfer efficiency and performance by ensuring uniform coolant distribution across the heat exchanger core, preventing dead zones and maintaining the capacity for a sufficient number of heat exchange elements within the housing, while allowing for flexible configuration based on the Water Charge Air-Cooler's orientation and layout.
Implementation Method 1
The first opening is for ingress of coolant inside the housing and around the airflow passages for extracting heat from air flowing through the airflow passages
Data Source
Figure 1~2a
Figure 2b
Figure 3~4
AI summary
A heat exchanger (100) includes a housing (110) receiving heat exchange elements (120) and defining airflow passages, a first and a second waterbox (112) and (114) respectively. The first waterbox (112) is in fluid communication with an interior (111) of the housing via a first opening (112a). The second waterbox (114) is in fluid communication with the interior (111) of the housing (110) via a second opening (114a). The at least one panel (130) is aligned with at least one of the first opening (112a) and the second opening (114a) to limit flow there through. Each panel (130) includes apertures (132) and deflectors (134). The apertures (132) are adapted to uniformly distribute coolant flowing there through. The plurality of deflectors (134) are protruding from the apertures (132) towards the inner volume of the respective waterbox (112, 114) and are connected to the inner surface of the waterbox (112, 114).