Ceramic Heat Exchanger Core With Varying Twist Angles
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Solution Overview
Problem
There is a need to develop heat exchangers with increased efficiencies and reduced costs, bridging the gap between standard industry and regenerative systems, which are cost-prohibitive due to complex designs.
Innovation Solution
A ceramic-based heat exchanger component with varying twist angles of spirals, featuring multiple fluid flow paths and a central cavity, optimized for high-temperature applications, enhancing heat exchange efficiency and reducing manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a uniform twist angle is used throughout the heat exchanger core, then the manufacturing process is simple, but the heat transfer efficiency is insufficient in regions with varying flow conditions
Solution Approach 1:
The patent applies local quality by varying the twist angle of the corrugated plates according to their position within the heat exchanger core. Different regions have different twist angles optimized for their specific flow conditions, with the twist angle varying continuously or in steps from the inlet to outlet regions, thereby optimizing heat transfer efficiency locally while maintaining manufacturing feasibility
Solution Approach 2:
The patent implements parameter changes by modifying the twist angle parameter of the corrugated plates across different positions. The twist angle is changed as a function of position (e.g., linearly or non-linearly varying), allowing the heat exchanger to adapt to varying flow conditions throughout the core while maintaining a relatively simple manufacturing process
2Productivity
If the twist angle varies continuously throughout the heat exchanger core, then the heat transfer efficiency is optimized, but the manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the heat exchanger core into multiple zones or sections, where each zone has a specific twist angle or a limited range of twist angles. This segmentation allows the complex varying twist angle profile to be approximated through discrete steps, optimizing heat transfer while simplifying manufacturing compared to truly continuous variation
Solution Approach 2:
The patent implements local quality by optimizing the twist angle in each local zone independently based on the flow conditions in that region. Each zone's twist angle is tailored to its specific hydraulic and thermal conditions, creating a piecewise optimized structure that balances performance with manufacturability
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 heat exchanger achieves high efficiency of up to 90% with low pressure drop and simplified manufacturing, utilizing a ceramic material that withstands high temperatures and pressures, and maintains consistent channel sizes throughout.
Implementation Method 1
The first and second sets of corrugated plates may have different twist angles to promote turbulence and enhance heat transfer
Data Source
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AI summary
A component for a heat exchanger can comprise a body including a ceramic and can have a central cavity extending along a length of the body; a plurality of spirals extending around the central cavity; a plurality of interspiral channels disposed between the plurality of spirals; a plurality of intraspiral channels contained within the plurality of spirals; wherein a twist angle of each spiral of the plurality of spirals in relation to a length direction of the body is varying. The heat exchanger component can be used for making a heat exchanger having three flow paths and can reach an exceptional efficiency while allowing an economic manufacturing.