Heat Exchanger Coupling for Thermal Expansion Management

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Solution Overview

Problem

Combination heat exchangers face failures due to varying degrees of thermal expansion between manifold tanks, leading to deformation and potential failure, and existing solutions with mechanical attachments add weight and complexity.

Innovation Solution

A coupling system with a thermal expansion feature that allows relative movement between heat exchanger cores, using an arcuate shape to accommodate thermal expansion and distribute stress, thereby preventing deformation and failure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of stationary object

If a common manifold tank is used for both heat exchanger cores, then packaging size is minimized, but thermal expansion differences cause localized deformation and failure

Engineering Contradiction:

Improvepackaging sizeVSAvoidmanifold tank failure

Core Design Contradiction:

Volume of stationary objectVSReliability

Solution Approach 1:

The patent divides the manifold tank into separate first and second manifold tanks, each dedicated to a specific heat exchanger core. This segmentation allows each tank to experience uniform thermal expansion independently, eliminating the localized deformation and failure caused by differential thermal expansion in a common tank configuration.

Inventive Principle:

Principle #1Segmentation

2Reliability

If separate manifold tanks are used for each heat exchanger core, then thermal expansion issues are resolved, but weight and device complexity increase due to mechanical attachment structures

Engineering Contradiction:

Improvethermal expansion accommodationVSAvoidmechanical attachment structures

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the first and second manifold tanks into a single integrated manifold assembly where the tanks are coupled through a shared structure. This integration eliminates the need for separate mechanical attachment structures, reducing weight and device complexity while maintaining the thermal expansion benefits of separate tank configuration.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated manifold assembly serves multiple functions: it provides separate chambers for each heat exchanger core to accommodate differential thermal expansion, maintains fluid communication between cores, and eliminates the need for additional mechanical attachment components. This multi-functionality reduces overall device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If separate manifold tanks are used with mechanical attachments, then thermal expansion is accommodated, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvethermal expansion managementVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

By integrating the manifold tanks into a single molded assembly, the patent reduces the number of discrete parts that need to be manufactured and assembled. This integration simplifies the manufacturing process, reduces assembly steps, and lowers production costs while maintaining the thermal expansion management capabilities.

Inventive Principle:

Principle #5Merging (Combining)

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 coupling system effectively manages thermal expansion without adding weight or complexity, ensuring the heat exchanger operates reliably by allowing for stress distribution and limited deformation, while resisting vibrations and maintaining structural integrity.

Implementation Method 1

when the first fluid and the second fluid have different temperatures, thereby causing each chamber formed in one of the common manifold tanks to be exposed to a different temperature than an adjacent chamber therein. This difference in temperature leads to varying degrees of thermal expansion occurring in each of the separated chambers.

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS10429133B2Heat exchanger element with thermal expansion feature

Publication Date: 2019.10.01 HANON SYST CO LTD

AI summary

A combination heat exchanger comprises a first heat exchanger assembly and a second heat exchanger assembly. The first heat exchanger assembly includes a first end tank, a second end tank, and a first heat exchanger core including a plurality of first heat exchanger tubes extending longitudinally in a first direction. The second heat exchanger assembly includes a third end tank, a fourth end tank, and a second heat exchanger core including a plurality of second heat exchanger tubes extending longitudinally in the first direction. A first coupling includes a first attachment portion rigidly coupled to the first end tank, a second attachment portion rigidly coupled to the third end tank, and a thermal expansion portion extending between the first attachment portion and the second attachment portion. The first coupling allows for relative translation between the first end tank and the third end tank in the first direction.