Reinforced Heat Exchanger Plate with Folded Corner Elements
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Solution Overview
Problem
Existing heat exchanger designs for automotive vehicles are costly and lack sufficient mechanical resistance while maintaining flexibility, particularly in the interface between reinforcement and lower plates.
Innovation Solution
Incorporating reinforcing elements around only two corners of the lower plate, with a shape complementary to the plate's external surface, and a process of cutting and folding these elements in a single step to enhance mechanical resistance and flexibility at a reasonable cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a reinforcement plate is added between the fixation plate and the stack of plates, then mechanical resistance is improved, but device complexity and cost increase
Solution Approach 1:
The reinforcement plate is segmented by providing recesses that receive reinforcing elements (such as L-shaped or U-shaped metal strips) around the corners of the lower plate. This segmentation allows the reinforcement function to be distributed across multiple discrete elements rather than requiring a solid reinforcement plate, thereby reducing material usage and assembly complexity while maintaining mechanical resistance.
Solution Approach 2:
Reinforcement is applied locally only where needed - specifically around the corners of the lower plate where mechanical stress is highest. The recesses are positioned at these critical locations to receive the reinforcing elements, providing targeted reinforcement without adding complexity to the entire plate structure. This local quality approach ensures strength is enhanced precisely where required while keeping the overall device simple.
2Strength
If reinforcing elements are added around all four corners of the lower plate, then mechanical resistance is improved, but manufacturing cost increases
Solution Approach 1:
Instead of providing reinforcing elements around all four corners of the lower plate, the invention applies reinforcement partially - only around two opposite corners (typically the corners where the inlet and outlet ports are located). This partial action is sufficient to provide the necessary mechanical resistance for the application, while significantly reducing the number of reinforcing elements required, thereby lowering manufacturing cost and simplifying the assembly process.
3Strength
If the lower plate is made more rigid to withstand deformations, then mechanical resistance is improved, but flexibility to accommodate slight deformations is reduced
Solution Approach 1:
The lower plate is designed with local quality variations - the corners are reinforced with reinforcing elements to provide rigidity and withstand deformations, while the central and edge regions maintain their original flexibility. This allows the plate to be rigid where needed (at the corners) and flexible where needed (in the bulk), enabling it to accommodate slight deformations without compromising structural integrity.
Solution Approach 2:
The lower plate structure becomes a composite system combining the base plate material with reinforcing elements (such as metal strips). This composite structure provides the benefits of both materials - the base plate maintains flexibility and fluid circulation pathways, while the reinforcing elements add rigidity and resistance to deformations at critical locations.
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 optimal reinforcement and elasticity to the heat exchanger, allowing it to withstand slight deformations and maintain efficient fluid circulation, while reducing constraints and costs associated with traditional designs.
Implementation Method 1
a reinforcement plate (8) between the fixation plate (6) and the stack of plates (4), characterised in that the reinforcement plate (8) has two reinforcing elements (24) around two corners (26) of the lower plate (20)
Implementation Method 2
heat exchangers comprising stack of plates for the circulation of two fluids alternately between the adjacent pairs of plates
Data Source
Figure 1~2
Figure 3~4
AI summary
The heat exchanger (2) comprises a stack of plates (4) comprising a lower plate (20) onto which the other plates (22) are stacked. The heat exchanger (2) also comprises a fixation plate (6) and a reinforcement plate (8) between the fixation plate (6) and the lower plate (20). The reinforcement plate (8) has reinforcing elements (24) obtained from a cut and fold of the reinforcement plate (8) material.