Extruded Heat Exchanger Body With Meandering Flue Gas Path
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Solution Overview
Problem
Existing heat exchangers made from light metals, particularly those using extrusion, face challenges such as significant material loss due to machining requirements and suboptimal gas contact with duct walls, which increases production costs and labor intensity.
Innovation Solution
A heat exchanger design featuring two extruded parts with ribs forming a flue duct and flame receiving space, where the main flow direction is perpendicular to the extrusion direction, reducing the need for machining and material loss, and utilizing a flexible bonding agent for assembly, ensuring a high heat exchanging capacity and efficient manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If extrusion process is used to manufacture heat exchanger parts, then manufacturing ease and productivity are improved, but material loss due to machining requirements still occurs
Solution Approach 1:
The heat exchanger body is divided into multiple extruded parts that are assembled together using bonding agents. This segmentation allows each part to be manufactured by extrusion without subsequent machining, while the bonding assembly creates the final functional structure. The ribs on each part define flow paths that connect when assembled, eliminating the need for machining operations on individual parts.
Solution Approach 2:
Multiple extruded parts are merged through bonding to form the complete heat exchanger body. The bonding process combines the parts in such a way that the ribs between parts define continuous flue ducts and flame receiving spaces without requiring material removal. This merging approach achieves the final shape through addition rather than subtraction, preventing material loss.
2Ease of manufacture
If traditional extrusion with parallel flow direction is used, then manufacturing simplicity is maintained, but gas contact with duct walls is suboptimal reducing heat transfer efficiency
Solution Approach 1:
The patent changes the flow direction from parallel to perpendicular relative to the extrusion direction. This dimensional change allows the ribs to define meandering flow paths that increase the contact surface area between flue gases and the heat exchanger walls. The perpendicular orientation enables the gas to flow across multiple rib surfaces in sequence, maximizing heat transfer while maintaining extrusion manufacturing.
3Strength
If ribs are used to define flue ducts in extruded parts, then structural integrity and flow path definition are improved, but significant material must be removed by machining
Solution Approach 1:
Instead of creating flue ducts by removing material between ribs, the patent inverts the approach: the ribs themselves define the flow paths through their arrangement and spacing. The solid ribs remain intact to provide structural strength, while the spaces between them naturally form the flue ducts and flame receiving spaces. This inversion eliminates the need for machining while preserving both structural integrity and flow path definition.
4Adaptability or versatility
If cast heat exchanger bodies are used, then designer freedom is achieved, but production costs and labor intensity increase
Solution Approach 1:
The extrusion process is made multi-functional by designing parts where the same extruded structure serves multiple purposes: providing structural strength, defining flow paths, and creating heat transfer surfaces. The ribs simultaneously provide mechanical support and define the geometry of flue ducts and flame receiving spaces, eliminating the need for separate machining operations and reducing production complexity.
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 design minimizes material loss and machining needs, enhances gas contact with the heat exchanger walls, and allows for efficient, cost-effective production with improved heat transfer efficiency, suitable for various heating systems.
Implementation Method 1
WO 2010/098666 discloses a heat exchanger made using extrusion of light metal... The parts are connected to each other with the ribs facing each other... utilizing a flexible bonding agent for assembly
Implementation Method 2
Heat exchanger bodies made of light metal such as aluminum or aluminum alloy... has a body made of light metal which has a high heat exchanging capacity/volume ratio
Implementation Method 3
between the ribs a flue duct is defined having a main flow direction which extends in a direction substantially perpendicular to the extrusion direction... defining a meandering flow path of flue gasses
Data Source
AI summary
Heat exchanger, comprising a heat exchanger body made of light metal or light metal alloy, wherein the body comprises at least a flue duct and a flame receiving space, wherein the body comprises two parts at opposite sides of the flue duct and flame receiving space, said two parts substantially defining said flue duct and flame receiving space, wherein the flue duct and flame receiving space define a main flow direction for flue gas between an entry side of the flame receiving space and an outlet of the flue duct, wherein each of said parts comprises a first series of ribs extending into the space between said two parts and having a length direction substantially perpendicular to the main flow direction for flue gas, thus defining a meandering flow path of flue gasses between said flame receiving space and said outlet and a second series of ribs extending in said flame receiving space, wherein between the ribs of said second series of opposite parts an open space is provided.