Flat-Frame Heat Exchanger Structure Without Mesh Reinforcement
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Solution Overview
Problem
Manufacturing heat exchangers for micro-turbine cogeneration systems is challenging due to the complexity of producing metal meshes that can take on complex shapes, leading to increased production costs and assembly difficulties.
Innovation Solution
A heat exchanger design featuring a stack of flat distribution frames with internal support projections and alternating metal sheets, eliminating the need for external reinforcement, such as wire mesh, by integrating projections into the frames to enhance structural integrity and simplify manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal meshes with complex shapes are used to reinforce the heat exchanger, then structural strength is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent merges the reinforcement function into the distribution frames themselves by adding integrated ribs. Instead of using separate metal meshes to strengthen the structure, the frames are designed with built-in rib structures that provide the necessary mechanical support. This integration eliminates the need for additional reinforcement components and simplifies the manufacturing process while maintaining structural integrity.
Solution Approach 2:
The patent extracts and eliminates the complex metal mesh reinforcement from the design. By removing the need for separately manufactured and assembled metal meshes, the design achieves structural strength through the simplified integrated rib structure in the distribution frames, thereby reducing manufacturing complexity and cost.
2Reliability
If multiple separate components (metal meshes, distribution frames, metal sheets) are used, then structural integrity is improved, but assembly complexity increases
Solution Approach 1:
The patent combines multiple functions into fewer components. The distribution frames are designed with integrated ribs that simultaneously provide structural support and define fluid channels. The alternating arrangement of simplified frames and metal sheets creates a self-supporting structure that maintains structural integrity while reducing the number of separate components and assembly steps.
3Adaptability or versatility
If standard manufacturing processes are used for complex metal meshes, then manufacturing flexibility is maintained, but production cost and time increase
Solution Approach 1:
The patent changes the geometric parameters of the distribution frames by incorporating integrated rib structures. This modification allows the frames to provide structural support without requiring complex metal mesh components. The simplified geometry enables the use of standard manufacturing processes while significantly improving production efficiency and reducing costs.
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 design results in a more robust, cost-effective, and easier-to-manufacture heat exchanger with improved thermal efficiency and reduced assembly complexity, enabling standardization and economies of scale during mass production.
Implementation Method 1
metal sheets arranged alternately with the distribution frames according to the stacking to create thermal contact between said fluid zones
Implementation Method 2
Its essential function is to preheat the combustion air by recovering the thermal energy still present in the turbine exhaust gases
Data Source
Figure 1
Figure 2
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AI summary
The present invention relates to a heat exchanger (1) for preheating the combustion air of a microturbine in a cogeneration system. The structure of this heat exchanger (1) comprises an assembly of flat distribution frames (31, 31') and spacer metal sheets (32). Each distribution frame is defined by a contour enclosing a fluid zone (80) and is equipped with inlet ports (11) and outlet ports (11) for the passage of this fluid. The metal sheets (32) are supported by support protrusions (4) on the distribution frames (31, 31'), which simplifies the fabrication of the heat exchanger (1).