3D Printed Heating Surface Element for Plate Heat Exchanger
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional plate heat exchangers face limitations in mechanical strength and design flexibility due to manufacturing processes, particularly when dealing with high temperatures and complex geometries, which restrict the ability to produce undercuts and optimize flow mechanics.
Innovation Solution
A plate heat exchanger with 3D-printed heating surface elements featuring a wave-shaped structure with alternating wave troughs and crests, allowing for customized design and integration of undercuts, produced using laser sintering from metal powders, enabling enhanced strength and flow optimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional manufacturing processes (electrochemical etching, chemical etching, casting, electroplating, micromachining) are used to create heating surface elements, then the production process is well-established and reliable, but the design flexibility is limited and complex geometries including undercuts cannot be produced
Solution Approach 1:
The patent replaces conventional mechanical manufacturing processes (etching, casting, micromachining) with an additive manufacturing process (3D printing). This substitution enables the creation of complex geometries and undercuts that are impossible to achieve with traditional subtractive or formative methods, while maintaining manufacturing reliability through established 3D printing technology.
Solution Approach 2:
The patent changes the fundamental manufacturing parameter from subtractive/removal-based processes to additive/build-up processes. This parameter change allows for the creation of arbitrary geometries including undercuts, internal channels, and complex wave patterns that cannot be produced by etching or casting, thereby achieving both design flexibility and manufacturing feasibility.
2Strength
If thin sheets are folded into corrugated structures using press or forming tools, then the heating surface elements can be produced with wave-like structure, but the mechanical strength is limited and cannot accommodate high pressures and temperatures
Solution Approach 1:
The patent replaces the mechanical folding process with additive manufacturing. Instead of folding thin sheets which inherently limits strength, the 3D printing process builds up material layer by layer to create the wave-like structure with full material density and structural integrity, enabling the elements to withstand high pressures and temperatures.
Solution Approach 2:
The patent utilizes the inherent layer-by-layer structure of 3D printed materials to create composite-like properties within the single component. The additive manufacturing process allows for optimized material distribution and density variations within the wave-like structure, enhancing mechanical strength while maintaining the required geometric complexity.
3Ease of manufacture
If conventional forming processes are used to produce heating surface elements, then the production process is straightforward, but the geometry is restricted and undercuts perpendicular to pressing direction cannot be produced
Solution Approach 1:
The patent replaces conventional forming processes with additive manufacturing technology. This substitution eliminates the geometric restrictions inherent in pressing and forming operations, allowing undercuts and complex three-dimensional geometries to be produced directly from digital models without requiring complex tooling or multi-step processes.
Solution Approach 2:
The patent transitions from two-dimensional pressing operations to three-dimensional additive construction. This dimensional change enables the creation of complex geometries including undercuts, internal features, and variable cross-sections that cannot be achieved with planar forming tools, while maintaining production efficiency through automated layer-by-layer fabrication.
4Reliability
If the heating surface elements are soldered to separating plates at contact points, then thermal contact is established for heat exchange, but the assembly complexity increases and mechanical strength at joints is reduced
Solution Approach 1:
The patent merges the heating surface element with the separating plate into a single integrally printed component. This elimination of separate parts removes the need for soldering operations, reduces assembly complexity, and eliminates potential weak points at joints while maintaining effective thermal contact through the continuous material structure.
Solution Approach 2:
The patent extracts the soldering process and separate component assembly from the manufacturing workflow. By integrating the functions of the heating surface element and separating plate into one monolithic structure, the patent eliminates the thermal contact interface created by soldering, thereby removing the associated assembly complexity and joint strength limitations.
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 3D-printed heat exchanger achieves improved mechanical strength, flexibility in design, and efficient heat transfer with reduced material usage and assembly complexity, accommodating complex geometries and flow requirements effectively.
Implementation Method 1
produced using laser sintering from metal powders
Implementation Method 2
indirectly transfer heat from a first fluid to a second fluid
Implementation Method 3
the fluids are guided in separate heat exchange passages within the plate heat exchanger
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to a heating surface element (2, 3) for a plate heat exchanger (10); said heating surface element (2, 3) is designed and provided to be placed between two parallel separation walls (4) of the plate heat exchanger such that a plurality of ducts (31) for holding a fluid is formed. According to the invention, the heating surface element (2, 3) is produced using 3D printing. The invention further relates to a plate heat exchanger and a method for producing a heating element and a plate heat exchanger.