Plate-Fin Heat Exchanger Box Partitioning for Flexible Flow Allocation
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Solution Overview
Problem
Existing heat exchanger manufacturing methods, such as custom and standardized matrix designs, face challenges in adapting to variable fluid pressures and flow rates, leading to high costs and inefficient energy usage due to over- or under-configuration of matrices in air separation units and other applications.
Innovation Solution
A method for manufacturing heat exchangers with adaptable fluid distribution systems, where the number of passages for each fluid is adjusted post-manufacture by partitioning the distribution boxes, allowing for flexible configuration without altering the exchanger's dies, enabling economies of scale and reduced manufacturing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If custom-made heat exchangers are manufactured to adapt to variable fluid pressures and flow rates, then adaptability to customer demand is improved, but manufacturing cost and manufacturing time increase significantly
Solution Approach 1:
The heat exchanger is divided into modular components: standardized matrices that can be manufactured in advance and distribution boxes that can be configured differently. This segmentation allows the majority of the exchanger (matrices) to be produced efficiently in series, while only the distribution boxes need customization to meet specific customer requirements for fluid pressures and flow rates.
Solution Approach 2:
The standardized matrices are manufactured in advance and stored for future use. This preliminary production of common components eliminates the need to manufacture entire custom exchangers for each customer order, significantly reducing both manufacturing cost and time while maintaining adaptability through different distribution box configurations.
2Adaptability or versatility
If custom-made heat exchangers are manufactured to adapt to variable fluid pressures and flow rates, then adaptability to customer demand is improved, but manufacturing time increases significantly
Solution Approach 1:
By segmenting the heat exchanger into pre-manufactured matrices and configurable distribution boxes, the manufacturing process is divided into a one-time setup for matrices and quick assembly operations for distribution boxes. This dramatically reduces manufacturing time for each custom order while maintaining full adaptability.
Solution Approach 2:
The standardized matrices are produced in advance and kept in inventory. When a custom order comes in, only the distribution boxes need to be configured and assembled with the pre-made matrices, reducing manufacturing time from weeks to days or hours while still meeting specific customer requirements.
3Productivity
If standardized matrices are used with fixed configuration, then manufacturing efficiency is improved, but adaptability to variable fluid demands deteriorates
Solution Approach 1:
The system is segmented into fixed standardized matrices (for efficiency) and variable distribution boxes (for adaptability). This allows the bulk of the manufacturing to be standardized and efficient, while the distribution boxes provide the necessary customization for different fluid pressures and flow rates without requiring custom matrix production.
Solution Approach 2:
The distribution boxes are designed to be dynamically reconfigurable through different partitioning arrangements. This dynamic capability allows the same standardized matrices to serve multiple applications with varying fluid demands, combining manufacturing efficiency with operational adaptability.
4Adaptability or versatility
If more matrices are put in series to meet specifications, then adaptability to fluid demands is improved, but cost increases
Solution Approach 1:
Instead of increasing the number of matrices throughout the entire system, the invention applies localized customization only where needed - in the distribution boxes. This allows adaptation to fluid demands without unnecessarily increasing the total quantity of matrices, reducing cost while maintaining performance.
5Ease of manufacture
If fewer matrices are put in series to reduce cost, then manufacturing cost is reduced, but energy efficiency deteriorates
Solution Approach 1:
The invention optimizes energy efficiency locally within the distribution boxes rather than requiring additional matrices. By configuring the partitioning means to match actual fluid flow requirements, the system achieves energy efficiency without increasing the number of matrices, thus avoiding additional manufacturing costs.
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 approach allows for efficient energy usage and cost reduction by enabling precise allocation of fluid passages post-manufacture, maintaining consistent interfaces and reducing manufacturing time while accommodating variable fluid demands.
Implementation Method 1
passages adapted to allow the flow of at least a first fluid, a second fluid and a third fluid through the matrix, so that the third fluid can heat or be heated by the first and second fluids
Implementation Method 2
plurality of passages which are delimited by the stack of laminations and corrugations to allow the flow of at least a first fluid and a second fluid through the exchanger which exchange their heat
Data Source
Figure 1~2
Figure 3~4
AI summary
In a process for manufacturing a series of at least one first and a second plate and fin heat exchangers (10), each having at least one fluid distribution box (24) covering at least a portion of the openings (20) of the matrix and which is connected to a conduit (30), the box (24) is partitioned into several compartments (28) by at least one partition (32,34), to distribute the number of openings (20) assigned to a first fluid (A) and a second fluid (B), the partition (32,34) being designed to divide said box into several compartments (28) which are each connected to a conduit (30, 40) for the passage of the first fluid (A) or the second fluid (B) and which each communicate with a number of openings (20) varying according to the configuration adopted for the exchanger of the series by the at least one partition (32,34).