Multi-layer Heat Exchanger Fin Redirection

Solution Overview

Problem

Multi-layer and multi-fluid plate and fin heat exchangers require multiple angled fin sections to redirect fluid flow, increasing part count and fabrication complexity, leading to higher costs.

Innovation Solution

A multi-layer heat exchanger design with a fluid layer featuring a single, uniform fin segment and apertures at the inlet end region to redirect fluid flow efficiently, reducing the need for multiple fin sections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If multiple angled fin sections are used to redirect fluid flow, then fluid flow redirection is achieved, but part count increases and fabrication complexity increases

Engineering Contradiction:

Improvefluid flow redirectionVSAvoidpart count

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

Multiple separate fin sections are merged into a single integrated fin structure with varying thickness. The fin includes a thick end portion near the inlet port and a thin end portion extending toward the outlet, eliminating the need for multiple discrete fin components while maintaining effective flow redirection functionality

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The fin structure employs local quality variation through non-uniform thickness distribution. The thick end portion provides structural support and effective flow interception near the inlet, while the thin end portion reduces material usage and fabrication complexity in regions where less structural support is needed, optimizing both performance and manufacturability

Inventive Principle:

Principle #3Local quality

2Ease of operation

If multiple angled fin sections are used to redirect fluid flow, then fluid flow redirection is achieved, but fabrication complexity increases

Engineering Contradiction:

Improvefluid flow redirectionVSAvoidfabrication complexity

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

Multiple separate fin sections are merged into a single integrated fin structure with varying thickness. The fin includes a thick end portion near the inlet port and a thin end portion extending toward the outlet, eliminating the need for multiple discrete fin components while maintaining effective flow redirection functionality

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The fin geometry is defined by continuous parameter variation, specifically the thickness parameter that transitions from thick at the end portion near the inlet to thin at the end portion extending toward the outlet. This gradual parameter change enables simplified manufacturing processes compared to assembling multiple discrete components with different geometries

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If multiple angled fin sections are used per fluid layer, then fluid flow redirection is achieved, but overall cost increases

Engineering Contradiction:

Improvefluid flow redirectionVSAvoidoverall cost

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

Multiple separate fin sections are merged into a single integrated fin structure with varying thickness. The fin includes a thick end portion near the inlet port and a thin end portion extending toward the outlet, eliminating the need for multiple discrete fin components while maintaining effective flow redirection functionality

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single fin structure performs multiple functions: it provides structural support through its thick end portion, redirects fluid flow effectively, and reduces material usage through its thin end portion. This multi-functional design eliminates the need for multiple specialized components, reducing overall system cost

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 simplifies the heat exchanger structure, lowers part count, and reduces manufacturing costs by facilitating efficient fluid flow redirection with fewer fin segments.

Implementation Method 1

the at least one fin segment includes a first plurality of apertures proximate the inlet end region

Methodology Applied

Scientific EffectFluid flow redirection:

Data Source

PatentUS10976117B2Multi-layer heat exchanger and method of distributing flow within a fluid layer of a multi-layer heat exchanger

Publication Date: 2021.04.13 HAMILTON SUNDSTRAND SPACE SYST INT INC

AI summary

A multi-layer heat exchanger includes a fluid layer defined by a first sheet and a second sheet, the fluid layer configured to route a fluid in a predominant flow direction. Also included is a fluid inlet port disposed proximate an inlet end region of the fluid layer, wherein the fluid inlet port is oriented to introduce the fluid into the fluid layer in a direction substantially perpendicular to the predominant flow direction, wherein the inlet end region of the fluid layer comprises a non-linear geometry. Further included is at least one fin segment disposed between the first sheet and the second sheet, wherein the at least one fin segment includes a first plurality of apertures proximate the inlet end region, the at least one fin segment consisting of a single, uniform fin segment.