Expanded Metal Exchange Plate for Heat-Humidity Transfer

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Solution Overview

Problem

Existing air-to-air counterflow enthalpy heat exchangers face challenges in achieving efficient heat and humidity transfer due to weak supporting structures, low thermal conductivity, and material waste during perforation processes, which hinder perfect heat and humidity exchange between supply and exhaust air.

Innovation Solution

The method involves creating an expanded metal structure from thin metal foil by slitting and stretching it, followed by rolling to increase surface area without waste, and then applying a vapour-permeable polymeric membrane, with subsequent shaping to induce turbulent flow for enhanced heat and humidity transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a non-woven fabric supporting structure is used, then the manufacturing process is simple, but the strength, stiffness, and thermal conductivity are low

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidsupporting structure strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent changes the material parameter from non-woven fabric to expanded metal foil, which fundamentally alters the strength, stiffness, and thermal conductivity properties while maintaining manufacturability through the expansion process

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite structure by combining expanded metal foil with a polymeric vapour-permeable membrane, achieving both mechanical strength and humidity exchange functionality

Inventive Principle:

Principle #40Composite materials

2Quantity of substance

If perforation is used to create exchange areas, then humidity exchange is enabled, but material waste is generated

Engineering Contradiction:

Improvemoisture exchange areaVSAvoidmaterial waste

Core Design Contradiction:

Quantity of substanceVSLoss of substance

Solution Approach 1:

The patent uses expanded metal foil with inherently porous structure created by the expansion process, eliminating the need for additional perforation operations and avoiding material waste while maintaining structural integrity

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent extracts the need for perforation by using the expanded metal structure itself as the vapour-permeable medium, removing the harmful perforation step that causes material waste

Inventive Principle:

Principle #2Taking out (Extraction)

3Ease of manufacture

If the supporting structure has low thermal conductivity, then manufacturing is easier, but heat transfer efficiency decreases

Engineering Contradiction:

Improvemanufacturing easeVSAvoidheat transfer efficiency

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The patent changes the thermal conductivity parameter by selecting expanded metal foil with high thermal conductivity, directly improving heat transfer efficiency while the expansion process maintains manufacturing feasibility

Inventive Principle:

Principle #35Parameter changes

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 results in a more efficient heat and humidity exchange with reduced material waste, improved thermal conductivity, and effective turbulent flow, enhancing the heat transfer efficiency between supply and exhaust air.

Implementation Method 1

creating an expanded metal structure from thin metal foil by slitting and stretching it, followed by rolling to increase surface area without waste

Methodology Applied

Scientific EffectMetal expansion:

Implementation Method 2

applying a vapour-permeable polymeric membrane

Methodology Applied

Scientific EffectVapour permeation: Permeation

Implementation Method 3

subsequent shaping to induce turbulent flow for enhanced heat and humidity transfer

Methodology Applied

Scientific EffectTurbulent flow: Turbulence

Implementation Method 4

efficient heat and humidity transfer between supply and exhaust air

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS11850651B2Method of manufacturing a heat-humidity exchange plate of an enthalpy air-to-air exchanger

Publication Date: 2023.12.26 RECUTECH SRO

AI summary

A heat and humidity exchange plate for an air-to-air heat exchanger is made by continuously forming an expanded metal structure from a strip of metal foil by slitting the metal foil in a transverse direction, stretching the metal foil in a longitudinal direction, and then rolling over an entire width of the strip of metal foil. The expanded metal structure is subjected to an annealing heat treatment. A vapour-permeable polymeric membrane is provided on the annealed expanded metal structure. Corrugated and embossed-shaped elements are formed on the annealed expanded metal structure with the vapour-permeable polymeric membrane by means of omnidirectional deformation. A circumferential shape of the exchange plate is formed by removing excess edges from the annealed expanded metal structure with the vapour-permeable polymeric membrane.