Flex Beam Support for Heat Exchanger Core Stress Relief

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Solution Overview

Problem

Heat exchangers experience significant thermal and mechanical stresses at the connection points between the core and housing due to thermal differences and pressurization, leading to stress concentration and reduced efficiency.

Innovation Solution

A heat exchanger design that includes a flex beam supporting the core away from the pressure housing, allowing thermal and mechanical stresses to be decoupled by elongate pathways and flexible connections, reducing direct contact and stress concentrations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If the heat exchanger core is directly attached to the pressure housing, then structural simplicity is improved, but thermal and mechanical stress concentration worsens

Engineering Contradiction:

Improvestructural simplicityVSAvoidstress concentration

Core Design Contradiction:

Device complexityVSStress or pressure

Solution Approach 1:

A flex beam is introduced as an intermediary component between the heat exchanger core and the pressure housing. The flex beam includes a core end connected to the core and a housing end connected to the housing, creating a flexible connection that decouples direct attachment while reducing stress concentration through elongate thermal and mechanical pathways.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If the heat exchanger core is directly attached to the pressure housing, then manufacturing simplicity is improved, but thermal stress generation worsens

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidthermal stress

Core Design Contradiction:

Ease of manufactureVSTemperature

Solution Approach 1:

The flex beam serves as a thermal intermediary that separates the core from the housing, creating elongate thermal pathways that reduce direct thermal coupling and minimize thermal stress generation during temperature variations.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Strength

If the heat exchanger core is directly attached to the pressure housing, then structural rigidity is improved, but mechanical stress concentration worsens

Engineering Contradiction:

Improvestructural rigidityVSAvoidmechanical stress concentration

Core Design Contradiction:

StrengthVSStress or pressure

Solution Approach 1:

The flex beam functions as a flexible connection element that replaces rigid direct attachment. The flexible beam maintains structural integrity while accommodating mechanical stresses through controlled flexibility, reducing stress concentration at the core-housing interface.

Inventive Principle:

Principle #30Flexible shells and thin films

4Stress or pressure

If the heat exchanger core is suspended away from the pressure housing, then stress concentration is reduced, but device complexity worsens

Engineering Contradiction:

Improvestress concentrationVSAvoidstructural complexity

Core Design Contradiction:

Stress or pressureVSDevice complexity

Solution Approach 1:

The flex beam's physical parameters (length, cross-section, material properties) are optimized to achieve the desired balance between stress reduction and structural simplicity. The elongate dimensions and flexible characteristics are specifically designed to minimize stress while maintaining manufacturability.

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

The design enhances efficiency and operating life by minimizing thermal and mechanical stresses, allowing higher temperature operation and reducing downtime while providing cost savings.

Implementation Method 1

Thermal stresses are generated at the connection points because of thermal differences between the core and the housing. The flex beam includes a core end connected to the heat exchanger core and a housing end spaced along the flex beam from the core end and connected to the pressure housing.

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 2

Additional mechanical stresses are also typically experienced at the connection points due to pressurization within the housing. The flex beam supports the heat exchanger core within the core chamber such that a spacing gap is formed radially between the heat exchanger core and the pressure housing.

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS12487037B2Flexural support for heat exchanger cores

Publication Date: 2025.12.02 HAMILTON SUNDSTRAND CORP

AI summary

A heat exchanger includes a heat exchanger core, a pressure housing, and a flex beam. The pressure housing at least partially defines a core chamber. The flex beam extends between and connects the heat exchanger core and the pressure housing such that the heat exchanger core is suspended away from the pressure housing within the core chamber by the flex beam. The flex beam includes a core end connected to the heat exchanger core and a housing end spaced along the flex beam from the core end and connected to the pressure housing.