Heat Exchanger Core Segmentation
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Solution Overview
Problem
Heat exchanger cores face challenges in achieving thermal effectiveness while minimizing size and mass, particularly in co-flow and counter-flow configurations, where reducing channel length to enhance tortuosity leads to increased plate area ratios and difficulties in fluid connection using conventional piping arrangements.
Innovation Solution
A heat exchanger core design featuring interleaved plates with multiple groups of parallel channels and intersecting distribution channels, allowing for high tortuosity and efficient heat exchange while maintaining suitable plate dimensions for fluid connection, achieved by forming platelets with zig-zag channels and strategically arranging ports and distribution channels for optimal fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If channel length is reduced to enhance tortuosity, then thermal effectiveness is improved, but plate area utilization deteriorates
Solution Approach 1:
The plate is divided into multiple platelets, each containing a group of parallel channels. This segmentation allows the fluid flow path to be distributed across multiple smaller channel groups, achieving high tortuosity and thermal effectiveness while maintaining reasonable individual channel lengths and plate area utilization.
Solution Approach 2:
The invention transitions from traditional single-channel configurations to multi-platelet arrangements with intersecting distribution channels. By adding the dimension of multiple platelets stacked and interleaved, the system achieves high tortuosity without proportionally increasing plate area requirements, as the heat exchange occurs across multiple stacked surfaces rather than requiring a single large plate area.
2Volume of moving object
If plate dimensions are reduced to maintain area relativities, then compactness is improved, but ease of fluid connection deteriorates
Solution Approach 1:
By segmenting the plate into multiple platelets with concentrated ports, the invention allows smaller overall plate dimensions while maintaining convenient connection points. The ports are strategically positioned to facilitate fluid connection even as the overall plate size is reduced for compactness.
Solution Approach 2:
The distribution channels serve multiple functions: they distribute fluid to multiple platelets, provide structural support, and enable compact arrangement of multiple heat exchange paths within a smaller footprint. This multi-functionality allows the system to maintain ease of fluid connection while achieving greater compactness.
3Area of stationary object
If tortuosity is increased to minimize heat exchange area, then thermal performance is improved, but channel length is reduced
Solution Approach 1:
The fluid path is segmented into multiple passes through different platelets, creating high tortuosity within a compact volume. Each platelet contains parallel channels that work together to achieve the required tortuosity and heat exchange area without requiring excessively long individual channels.
Solution Approach 2:
Multiple platelets are nested or stacked within the same plate structure, allowing the fluid to traverse through multiple heat exchange surfaces in sequence. This nesting approach increases the effective heat exchange area and tortuosity without proportionally increasing the overall channel length, as the paths are arranged in a compact stacked configuration.
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 design optimizes heat exchange area and facilitates convenient fluid connection, reducing stress-induced bending and thermal expansion issues, while maintaining compactness and efficient thermal performance.
Implementation Method 1
stacking and diffusion bonding the plates to form cores
Implementation Method 2
Heat exchanger core... channels for heat exchange fluids... each one of the platelets in the plates of the first group is located in heat exchange juxtaposition with a respective one of the platelets in the plates of the second group
Data Source
AI summary
A heat exchanger core incorporating diffusion bonded plates and heat exchangers incorporating such core are disclosed. The heat exchanger core comprises first and second groups of interleaved plates which are arranged respectively to carry first and second heat exchange fluids, and each of the plates in each group is formed in one of its faces with thirty or more platelets, each of which is composed of a group of parallel channels. Ports extend through the first and second groups of plates for conveying the first and second heat exchange fluids to and from the platelets, and distribution channels connect opposite ends of each platelet in each of the plates to associated ones of the ports. The distribution channels that are associated with each of the platelets in the plates of the first group are disposed in intersecting relationship with the distribution channels that are associated with respective ones of the platelets in the plates of the second group whereby each one of the platelets in the plates of the first group is located in heat exchange juxtaposition with a respective one of the platelets in the plates of the second group.