Composite Tube Plate Structure for Corrosion and Load Stability
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Solution Overview
Problem
Existing tube sheets for downstream heat exchangers, particularly those made of plastic, are prone to deformation and material stress under kinetic and thermal loads, leading to potential damage and increased costs with steel alternatives.
Innovation Solution
A five-layer tube sheet design featuring three middle layers of stainless steel plates and outer layers of corrosion-resistant materials, such as Teflon, which are connected to form a stable and corrosion-resistant composite structure, reducing material stress and simplifying production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If tube sheets are made of plastic, then production cost is reduced and resistance to acids and pollutants is improved, but stability under kinetic and thermal loads deteriorates leading to deformation and damage
Solution Approach 1:
The patent applies composite materials by combining plastic and metal layers to create a tube sheet that exhibits both the corrosion resistance and cost benefits of plastic and the mechanical strength and thermal stability of metal. The composite structure integrates a plastic layer with metal layers (such as aluminum or steel) through bonding processes, resulting in a material that resists acids and pollutants while maintaining stability under kinetic and thermal loads during heat exchanger operation.
2Strength
If tube sheets are made of steel, then stability under kinetic and thermal loads is improved, but production cost increases
Solution Approach 1:
The patent uses composite materials to achieve the mechanical strength of steel at reduced cost. By combining a thinner or smaller proportion of metal layers with plastic layers, the tube sheet maintains adequate stability under kinetic and thermal loads while reducing the amount of expensive metal material required, thereby lowering production costs compared to solid steel tube sheets.
Solution Approach 2:
The patent applies local quality by concentrating metal layers only in specific regions where high mechanical strength and thermal resistance are most needed, such as areas subjected to highest thermal loads or kinetic stresses. This allows the tube sheet to achieve necessary stability while using metal material only where required, reducing overall production cost compared to uniform steel construction.
3Object-affected harmful factors
If tube sheets are made of plastic, then resistance to acids and pollutants is improved, but occurrence of material stress deteriorates leading to potential damage
Solution Approach 1:
The patent employs composite materials where the plastic layer provides resistance to acids and pollutants while the metal layer provides structural support that reduces material stress. The bonding between layers creates a synergistic effect where each material compensates for the other's weaknesses, maintaining reliability by reducing material stress while preserving chemical resistance.
Data Source
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AI summary
The tube plate (100) has a central sheet (11), an exhaust gas-sided tube plate sheet (12), a hydraulic tube plate sheet (13), sealing ring (14), corrosion protection sheet(15) and an outer sheet (16) connected with each other. The sheets (11, 12, 13, 16) are made of metal i.e. stainless steel. The outer sheet is made of corrosion resistant material such as thermoplastic resin e.g. polytetrafluoroethylene. Receiving openings (20) receive tubes of a downstream heat exchanger, where the tubes are made of glass.