Flow Reactor Ridges Enhance Heat Exchange
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Solution Overview
Problem
Existing flow reactors face challenges in achieving efficient thermal control and maximizing heat exchange performance, particularly in maintaining high chemical resistance and mechanical strength while optimizing turbulence and secondary flows within the heat exchange fluid passages.
Innovation Solution
The flow reactor module incorporates a process fluid module with two or more raised ridges on the interior surfaces of the heat exchange fluid enclosures, which act as baffles to enhance turbulence and optimize the Reynolds number within the heat exchange fluid path. The gap between the ridges and the major surfaces is strategically enlarged to balance mechanical separation and heat exchange performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If small protuberances or turbulators are used on the inner surface of heat exchange enclosures to increase turbulence, then heat exchange performance is improved, but mechanical strength and chemical resistance of the ceramic module are compromised
Solution Approach 1:
The patent applies local quality by placing raised ridges only at specific locations on the heat exchange enclosure surfaces that contact the ceramic module, rather than modifying the entire ceramic surface. The ridges are positioned to create turbulence in the heat exchange fluid paths while leaving the ceramic module itself intact and preserving its mechanical strength and chemical resistance properties.
Solution Approach 2:
The raised ridges act as an intermediary element between the heat exchange fluid and the ceramic process fluid module. Instead of directly modifying the ceramic module to create turbulence (which would compromise its strength), the ridges are placed on the heat exchange enclosure surfaces to mediate the fluid flow and create the desired turbulence effect without damaging the ceramic structure.
2Productivity
If the gap between heat exchange enclosures and process fluid module is reduced to improve thermal contact, then heat exchange efficiency is improved, but mechanical separation and protection of the ceramic module are compromised
Solution Approach 1:
The patent applies local quality by creating localized contact points through raised ridges at specific locations on the heat exchange enclosures, rather than requiring uniform tight contact across the entire surface. This allows the gap to be maintained for mechanical protection while still achieving effective thermal contact at the ridge locations where turbulence is generated.
Solution Approach 2:
The patent segments the heat exchange contact interface by using discrete raised ridges rather than continuous contact. This segmentation allows different regions to serve different functions: the ridges provide localized thermal contact and turbulence generation, while the gaps between ridges maintain mechanical separation and protection of the ceramic module.
3Productivity
If raised ridges are added to heat exchange enclosures to enhance turbulence, then device complexity increases, but heat exchange performance is improved
Solution Approach 1:
The patent uses curved or rounded raised ridges on the heat exchange enclosure surfaces rather than sharp angular features. This curvature approach generates effective turbulence in the fluid flow while maintaining a relatively simple manufacturing process and avoiding excessive structural complexity. The smooth curved surfaces are easier to manufacture than complex angular geometries.
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 configuration optimizes the average Reynolds number within the heat exchange fluid path, enhancing heat exchange performance while maintaining the mechanical integrity and chemical resistance of the ceramic process fluid module.
Implementation Method 1
the interior surface of the first heat exchange fluid enclosure comprises two or more raised ridges extending in a second direction at least partially crosswise to the first direction... to enhance turbulence and optimize the Reynolds number within the heat exchange fluid path
Implementation Method 2
a first heat exchange fluid enclosure sealed against the first major surface of the process fluid module... an interior surface for containing heat exchange fluid against the first major surface... the second heat exchange fluid enclosure sealed against the second major surface
Data Source
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AI summary
A flow reactor includes a flow reactor module having a heat exchange fluid enclosure with an inner surface sealed against a surface of a process fluid module, the inner surface having two or more raised ridges crosswise to a heat exchange flow direction from an inflow port or location to an outflow port or location and having a gap of greater than 0.1 mm between the two or more raised ridges and the surface of the process module.