Area heater element, method for producing same and tool
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Solution Overview
Problem
Existing surface heat exchanger elements face challenges in manufacturing with minimal material usage while maintaining thermal efficiency, particularly when dealing with small pipe cross-sections that can lead to flow issues and evaporation problems.
Innovation Solution
The design incorporates a support plate with parallel, U-shaped pipe branches having smaller cross-sections than the connection cross-section, allowing for reduced material usage and optimized heat exchange, facilitated by a manufacturing method that uses heat transfer plates with grooved channels and a modified tooling process to accommodate circular pipe sections without deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If pipe cross-section is reduced to minimize material usage, then material consumption decreases, but fluid flow performance deteriorates and evaporation problems occur
Solution Approach 1:
The piping system is divided into multiple parallel pipe branches instead of using a single large-diameter pipe. Each branch has a smaller cross-section (6-9 mm) but collectively they provide sufficient flow capacity. This segmentation allows material reduction while maintaining overall flow performance through parallel pathways.
Solution Approach 2:
Different pipe cross-sections are used in different locations: smaller cross-sections (6-9 mm) in the parallel branches for material efficiency, and larger connection cross-sections (12-18 mm) at inlet/outlet connections for optimal fluid entry/exit. This local differentiation optimizes both material usage and flow performance.
2Loss of substance
If pipe cross-section is reduced, then material usage decreases, but start-up time increases due to fluid volume reduction
Solution Approach 1:
Multiple parallel pipe branches are implemented to distribute the fluid flow paths. Although each individual branch has reduced fluid volume, the parallel configuration provides multiple simultaneous flow paths, reducing the overall start-up time compared to a single large pipe with equivalent material content.
3Loss of substance
If pipe cross-section is reduced, then material usage decreases, but flow disruptions and evaporation issues arise
Solution Approach 1:
The flow path is segmented into multiple parallel branches, preventing flow stagnation and disruptions that would occur in a single narrow pipe. The parallel configuration ensures continuous flow distribution and reduces evaporation risks by maintaining adequate flow velocity across multiple pathways.
Solution Approach 2:
Larger connection cross-sections (12-18 mm) are provided at inlet and outlet connections to ensure smooth fluid entry and exit, preventing flow disruptions at these critical points despite the smaller branch cross-sections.
4Ease of manufacture
If conventional tooling is used for manufacturing, then manufacturing process remains simple, but pipe deformation occurs due to lack of accommodation for circular pipe sections
Solution Approach 1:
Heat transfer plates with grooved channels serve as intermediaries between the circular pipe sections and the flat support plate. The grooves accommodate the circular pipe cross-sections without deformation, allowing conventional pressing tools to be used while maintaining pipe integrity. The heat transfer plates transfer the pressing force evenly around the circular pipes.
5Power
If parallel pipe branches are implemented, then heat exchange efficiency improves, but device complexity increases
Solution Approach 1:
Multiple pipe branches are merged into a single support plate structure with integrated grooves. The heat transfer plates combine the functions of thermal conduction and mechanical support, while the grooves integrate multiple pipe accommodations into a unified manufacturing process. This merging reduces the complexity that would otherwise arise from assembling separate components.
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 approach enables efficient heat exchange with lower fluid volumes, reduced start-up times, and minimized material usage, while avoiding flow disruptions and evaporation issues, allowing for simple installation and fabrication.
Implementation Method 1
The straight pipe sections are fixed to the support plate by means of heat transfer plates
Data Source
Figure 1
Figure 1a
Figure 2
AI summary
The element (10) has a support plate (11) at which a piping system (13) is defined with the help of transfer of heat metal sheets (14a-14f), and an input terminal (15) and an output terminal (16). The input terminal and the output terminal are provided with a connection pipe portion (17) with a cross-section connection (18). A set of parallel switched spacer branches (19a-19c) is arranged with rectilinearly trained line sections (20a-20f). Each line section is arranged along a common flow direction (22) and has a pipe cross-section (24) that is smaller than connection cross-section. Independent claims are also included for the following: (1) a method for manufacturing a surface heat exchange element (2) a tool for manufacturing a surface heat exchange element.