Flexural Heat Exchanger Core Support for Thermal Stress Relief
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Solution Overview
Problem
Thermal and mechanical stresses at the connection points between heat exchanger cores and housings due to thermal differences and pressurization, leading to significant stress concentration and reduced efficiency.
Innovation Solution
A flexural support system using flex beams that connect the heat exchanger core to the pressure housing, allowing the core to float within a chamber and decouple thermal and mechanical stresses by providing elongate pathways for temperature gradients and pressure differentials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the heat exchanger core is directly attached to the pressure housing, then the structural simplicity and manufacturing ease are improved, but thermal and mechanical stresses concentrate at the connection points causing reduced reliability
Solution Approach 1:
A flex beam is introduced as an intermediary component between the heat exchanger core and the pressure housing. The flex beam suspends the core from the housing, eliminating direct attachment while maintaining structural support. This intermediary element allows thermal expansion and decouples mechanical stresses, preventing stress concentration at connection points and improving reliability.
Solution Approach 2:
The flex beam is designed as a flexible structural element that can deform under thermal and mechanical loads. This flexibility allows the core to expand and contract with temperature changes while the flex beam absorbs the resulting stresses, preventing crack initiation and propagation at the attachment points.
2Reliability
If the heat exchanger core is suspended away from the pressure housing using flex beams, then thermal and mechanical stresses are reduced improving reliability, but the device complexity increases
Solution Approach 1:
The flex beam performs multiple functions simultaneously: it provides structural support to suspend the core, allows thermal expansion through flexible deformation, decouples mechanical stresses from the housing, and maintains sealing to prevent fluid bypass. By consolidating these functions into a single component, the overall device complexity is minimized while achieving improved reliability.
3Reliability
If flex beams are used to suspend the core, then thermal expansion is allowed reducing stress concentration, but the manufacturing precision requirements increase
Solution Approach 1:
The flex beam's geometric parameters (cross-sectional dimensions, material properties, length) are optimized to provide adequate flexibility for thermal expansion while maintaining sufficient stiffness for structural support. By carefully selecting and designing these parameters, the system achieves reliable stress reduction without requiring excessive manufacturing precision in the final assembly.
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
Reduces thermal and mechanical stresses, enhances efficiency by allowing higher operating temperatures, and extends the lifespan of the heat exchanger by minimizing direct contact and stress concentrations.
Implementation Method 1
allowing for thermal expansion and decoupling of mechanical stresses
Implementation Method 2
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
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
A heat exchanger includes a heat exchanger core (14, 14'), a pressure housing (12, 12'), and a flex beam (16, 16'). The pressure housing (12, 12') at least partially defines a core chamber. The flex beam (16, 16') extends between and connects the heat exchanger core (14, 14') and the pressure housing (12, 12') such that the heat exchanger core (14, 14') is suspended away from the pressure housing (12, 12') within the core chamber by the flex beam (16, 16'). The flex beam (16, 16') includes a core end connected to the heat exchanger core (14, 14') and a housing end spaced along the flex beam (16, 16') from the core end and connected to the pressure housing (12, 12').