Heat Exchanger Core Structure for Outward Header Passages
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Heat exchanger cores manufactured by stacking plates are limited in shape, leading to excess areas that do not contribute to strength or heat exchange efficiency, increasing weight and manufacturing costs.
Innovation Solution
A heat exchanger core design with a core body having cavity portions forming channels and headers, where the headers are partially located outward from the channel arrangement, and the core body surface extends closer to the channel area than the header's outermost portion, optimized for additive manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the heat exchanger core is formed by stacking plates, then the manufacturing process is conventional and reliable, but the shape is restricted and excess areas increase weight and cost
Solution Approach 1:
The patent transitions from conventional plate stacking to additive manufacturing, fundamentally changing the manufacturing parameter from mechanical assembly to digital fabrication. This enables complex three-dimensional channel configurations and optimized heat exchange surfaces that were previously impossible to achieve with plate stacking methods.
2Ease of manufacture
If the overall shape is a simple pillar shape, then the manufacturing is simple, but excess areas do not contribute to strength or heat exchange efficiency, increasing weight and cost
Solution Approach 1:
The heat exchanger core is segmented into functional zones: channel formation areas with dense material for heat exchange, header areas with displaced passages for fluid distribution, and body side surfaces optimized for structural strength. This segmentation eliminates excess material while maintaining all necessary functions.
Solution Approach 2:
The patent utilizes three-dimensional additive manufacturing to create complex spatial configurations, including header passages that are partially displaced outward from the channel arrangement area. This dimensional freedom allows optimization of material distribution in all three dimensions, removing unnecessary material while preserving structural integrity and heat exchange efficiency.
3Ease of manufacture
If the header passage is located outward from the channel arrangement area, then the shape is optimized for additive manufacturing, but the structural support requirement increases
Solution Approach 1:
The body side surface is specifically positioned to extend along the channel extension direction at an optimized location between the channel arrangement area and the displaced header passage. This creates a localized structural reinforcement zone that provides necessary support for the outward-displaced header while maintaining overall weight reduction and manufacturing optimization.
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 reduces excess material, minimizing weight and manufacturing costs while enhancing heat exchange efficiency and manufacturing time.
Implementation Method 1
Heat exchangers are used in various devices, plants, etc., for the purpose of heating or cooling fluids
Data Source
AI summary
A heat exchanger core according to at least one embodiment is provided with: a core body having a plurality of cavity portions forming a plurality of channels inside the core body; and a header including a header passage communicating with the plurality of channels on at least one end side of the core body. The header passage is at least partially located in a region displaced outward from an arrangement area of the plurality of channels in plan view as viewed from a first extension direction of the plurality of channels. The core body has a body side surface extending along the first extension direction at a position closer to the arrangement area than a portion of the header passage that is farthest outward from the arrangement area in the plan view.