Heat exchanger assembly and method of assembly thereof
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Solution Overview
Problem
Existing dry cooler assemblies face challenges in withstanding external forces like strong winds and maintaining efficiency due to inadequate sealing and costly manufacturing processes.
Innovation Solution
A heat exchanger assembly with a frame supporting heat exchanger panels in a V-configuration, featuring a fan for air circulation, lateral and middle enclosing panels that form seals with the panels, and a weldless frame assembly using interlocking components to reduce costs and enhance structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional welding is used to assemble the frame, then structural strength is improved, but manufacturing complexity and production costs increase
Solution Approach 1:
The frame is divided into multiple modular components (side frames, end frames, cross members) that can be manufactured separately and assembled through interlocking mechanisms rather than welding. This segmentation allows for simplified manufacturing of individual parts while maintaining overall structural integrity through the interlocking assembly system.
Solution Approach 2:
The patent replaces the welding process (thermal/mechanical joining method) with a mechanical interlocking system using interlocking members, slots, and engagement features. This substitution eliminates the complexity of welding operations, equipment, and skill requirements while providing sufficient structural strength for the application.
2Reliability
If the frame is designed to withstand strong winds, then reliability is improved, but device complexity increases
Solution Approach 1:
The frame's wind resistance is achieved through segmented modular components that can independently absorb and distribute wind loads. The interlocking joints between segments provide flexibility to handle dynamic wind forces without requiring an overly complex monolithic structure.
Solution Approach 2:
The interlocking frame structure provides dynamic flexibility to withstand strong winds. The modular components can move slightly relative to each other through the interlocking mechanism, allowing the structure to flex and adapt to wind loads rather than being rigid and potentially brittle.
3Reliability
If the enclosed space is sealed, then heat rejection efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The sealing function is merged with the structural frame components. The interlocking joints that provide structural strength also create sealed enclosures when combined with the heat exchanger panels, eliminating the need for separate sealing systems and reducing manufacturing complexity.
Solution Approach 2:
The frame structure itself provides the sealing function through its interlocking design. The joints and connections between frame members and heat exchanger panels are designed to automatically seal the enclosed space, allowing the structure to serve both structural and sealing purposes without additional components.
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 solution provides enhanced structural stability against external forces and improved sealing efficiency without the need for conventional welding, reducing production costs and maintaining performance under varying environmental conditions.
Implementation Method 1
heat exchanger panels being configured for exchanging heat with air pulled into the heat exchanger assembly
Implementation Method 2
tubing arrangement for circulating fluid therein
Implementation Method 3
a fan for pulling air into an enclosed space of the heat exchanger assembly
Implementation Method 4
the first and second wall portions are deflected relative to one another by forces exerted thereon by the lower ends of the first and second heat exchanger panels causing a first seal to form
Data Source
AI summary
A heat exchanger assembly includes a frame; first and second heat exchanger panels configured for exchanging heat with air pulled into the heat exchanger assembly and disposed in a V-configuration; a fan for pulling air into an enclosed space of the heat exchanger assembly; a plurality of lateral enclosing panels and at least one middle enclosing panel. The at least one middle enclosing panel extends perpendicular to the lateral enclosing panels and is disposed between the heat exchanger panels. A U-shaped lower end of the at least one middle enclosing panel includes first and second wall portions opposite one another. The lower ends of the heat exchanger panels abut the wall portions such that the wall portions are deflected relative to one another by forces exerted thereon by the lower ends causing a first and second seals to form between the wall portions and the heat exchanger panels.