Deformable CWHE Supports for Precise Tube Layer Spacing
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Solution Overview
Problem
Existing coil-wound heat exchanger (CWHE) systems require multiple preformed supports tailored to specific tube bundle geometries, leading to increased production time and cost due to the need for different supports for each unique geometry.
Innovation Solution
The implementation of deformable support structures that can be formed into a final desired configuration during the tube winding process, allowing a single design to support individual tube layers with the necessary radial and axial stiffness, and optionally incorporating non-deformable portions to function as spacers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If preformed supports are used for each specific tube bundle geometry, then the structural integrity and spacing requirements are met, but the production time and cost increase due to needing different supports for each configuration
Solution Approach 1:
The patent applies universality by designing a single deformable support structure that can adapt to multiple tube bundle geometries. Instead of manufacturing different preformed supports for each configuration, one universal support design is used that deforms during the winding process to accommodate various tube diameters, layer spacings, and winding angles, thereby reducing production time while maintaining structural integrity
Solution Approach 2:
The patent applies dynamics by using supports that are deformable rather than rigid. The supports change their physical state during the winding process, allowing them to conform to different geometries. This dynamic adaptation enables a single support design to serve multiple configurations without requiring precise preformation for each case
2Manufacturing precision
If preformed supports are used for each specific tube bundle geometry, then the desired layer spacing and tube positioning are achieved, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent reduces device complexity by replacing multiple specialized support designs with a single universal deformable support. This universal support maintains manufacturing precision for layer spacing and tube positioning through its ability to deform and adapt to the specific geometry during installation, eliminating the need to manufacture and inventory multiple support types
Solution Approach 2:
The patent applies parameter changes by allowing the support's physical parameters (shape, volume, position) to change during the winding process. The support transitions from an undeformed state with uniform dimensions to a deformed state that conforms to the specific tube bundle geometry, thereby achieving precise layer spacing and positioning without requiring different support designs
3Device complexity
If deformable supports are used, then a common support structure can be used across various configurations reducing production complexity, but the ability to maintain precise spacing without separate spacers may be compromised
Solution Approach 1:
The patent merges the functions of the support and spacer into a single integrated component. The deformable support structure performs both the structural support function and the spacing function, eliminating the need for separate spacer components. The support deforms to provide both mechanical support and precise layer spacing simultaneously
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 solution enables the use of a common support structure across various CWHE configurations, reducing production complexity and costs while maintaining the required structural integrity and spacing between tube layers.
Implementation Method 1
a deforming force is applied to the second tube layer in a direction normal to the outer support surface of each of the plurality of first layer supports sufficient to cause the support to deform
Data Source
AI summary
A coil wound heat exchanger utilizing a deformable support system and method for making a tube bundle for the same includes a mandrel, a first tube layer formed by winding one or more tubes around the mandrel, and a plurality of supports and spacers circumferentially-arranged in an alternating pattern on an outer surface of the first tube layer. A second tube layer is formed by winding one or more tubes around the mandrel, whereby the second tube layer contacts an opposite side of the supports. A deforming force is applied to the second tube layer in a direction normal to the outer surface of each support, which causes the one or more tubes forming the second tube layer to deform the outer support surface of each support.