Heat Exchanger Closure Bar Moisture Prevention

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Solution Overview

Problem

Heat exchangers face damage due to moisture accumulation and subsequent freezing within the core assembly, which reduces operational life as frozen liquid expands and deforms components during temperature fluctuations.

Innovation Solution

A heat exchanger core assembly design featuring C-shaped closure bars with reinforcing bars that have tabs fitting within channels, eliminating gaps and preventing moisture accumulation, thereby preventing freezing damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional closure bars with gaps are used, then manufacturing is simpler, but moisture accumulates and causes freezing damage

Engineering Contradiction:

Improveoperational lifeVSAvoidclosure bar structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The closure bar is segmented into two distinct components: a C-shaped closure bar and a separate reinforcing bar with tabs. This segmentation allows each component to serve its specific function - the C-shaped bar provides the basic closure structure while the reinforcing bar with tabs prevents gap formation and moisture accumulation at the interface.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The reinforcing bar with tabs is nested within the C-shaped closure bar structure. The tabs of the reinforcing bar fit into the channel of the C-shaped bar, creating an interlocking arrangement that eliminates gaps. This nesting approach allows the smaller reinforcing elements to be integrated into the larger closure bar assembly.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

If reinforcing bars are added to closure bars, then moisture accumulation is prevented, but device complexity increases

Engineering Contradiction:

Improveresistance to freezing damageVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The reinforcing bar is merged with the closure bar through the tab-channel interface. The tabs of the reinforcing bar combine with the channel of the C-shaped closure bar to form a unified structure that prevents gap formation. This merging approach allows two components to function as a single integrated moisture barrier.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The reinforcing bars are positioned and secured within the C-shaped closure bars during assembly, before the heat exchanger is put into service. This preliminary action ensures that the gap-preventing structure is already in place before moisture accumulation can occur, proactively preventing the freezing damage problem.

Inventive Principle:

Principle #10Preliminary action

3Weight of moving object

If C-shaped closure bars are used instead of solid bars, then weight is reduced, but structural strength may be compromised

Engineering Contradiction:

Improveclosure bar weightVSAvoidclosure bar strength

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The C-shaped closure bar has varying wall thicknesses and structural properties at different locations. The walls are designed with appropriate thickness to provide sufficient strength at critical areas while maintaining weight reduction overall. The local quality of the material distribution optimizes the strength-to-weight ratio.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The closure bar system uses a composite structure combining the C-shaped bar material with the reinforcing bar material. This composite arrangement creates a stronger overall structure than either component alone, as the two materials work together to provide both weight efficiency and structural strength.

Inventive Principle:

Principle #40Composite materials

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 solution effectively prevents moisture accumulation and freezing damage, enhancing the operational life of the heat exchanger by ensuring no gaps form between the closure and reinforcing bars, thus maintaining structural integrity and performance.

Implementation Method 1

A reinforcing bar is received within a channel of the closure bar to create an interface with substantially no gaps to prevent accumulation of moisture within the core assembly

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Implementation Method 2

The closure bar includes a C-shaped cross-section to provide desired strength at a relatively low weight

Methodology Applied

Scientific EffectGeometric strength: Geometry

Data Source

PatentUS8276654B2Core assembly with deformation preventing features

Publication Date: 2012.10.02 HAMILTON SUNDSTRAND CORP

AI summary

A heat exchanger assembly includes a core assembly having air passages that are closed off on at least one side by a closure bar. A reinforcing bar is received within a channel of the closure bar to create an interface with substantially no gaps that may accumulate moisture within the core assembly. The prevention of moisture accumulation at the interface between the reinforcing bar and the closure bar prevents potential damage caused by freezing.