Heat Exchanger Hollow Elements with Integrated Protuberances
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Solution Overview
Problem
Existing heat exchangers for motor vehicles are complex, have high thermal resistance, and are difficult to assemble due to the large number of parts, particularly the fins, which limits their heat exchange efficiency and mechanical strength.
Innovation Solution
A heat exchanger design featuring hollow elements with protuberances that connect adjacent elements, allowing fluid communication and simplifying the structure by reducing the number of parts, with a manufacturing method involving stamping and brazing to form sealed mechanical connections, enhancing thermal conductivity and assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If fins are used to increase heat exchange surface, then heat exchange surface area is improved, but device complexity and assembly difficulty increase
Solution Approach 1:
The patent merges the fin structure with the hollow elements by integrating protrusions directly onto the hollow elements. These protrusions serve dual functions: they increase the heat exchange surface area and they act as connection means to join hollow elements together. This eliminates the need for separate fin components and their associated mounting hardware, thereby reducing device complexity while maintaining enhanced heat exchange capability.
2Area of moving object
If fins are mounted between hollow elements, then heat exchange surface is increased, but assembly difficulty increases
Solution Approach 1:
The fin structure is merged with the hollow elements through integrated protrusions that are formed as part of the hollow element manufacturing process. This integration eliminates the separate mounting step for fins, as the protrusions are already attached to the hollow elements before assembly. The protrusions serve both as heat exchange surfaces and as connection features, simplifying the assembly process significantly.
Solution Approach 2:
The protrusions are pre-formed on the hollow elements during manufacturing, before the assembly stage. This preliminary action of creating the heat exchange surfaces and connection means in advance eliminates the need for complex assembly operations, allowing workers to simply stack and connect the pre-prepared hollow elements.
3Reliability
If traditional heat exchanger design is used, then structure is established, but thermal resistance increases
Solution Approach 1:
The heat exchanger is segmented into multiple hollow elements with internal channels, allowing the first heat transfer fluid to flow through each element. The protrusions extend into the space between hollow elements, creating additional heat exchange pathways. This segmentation and distribution of fluid flow through multiple channels reduces thermal resistance by ensuring more uniform heat distribution and reducing hot spots.
Solution Approach 2:
The invention adds a third dimension to the heat exchange process by extending protrusions from the hollow elements into the inter-element space. This creates heat exchange surfaces that protrude outward, increasing the effective heat transfer area without increasing the footprint. The protrusions allow heat transfer to occur in multiple spatial dimensions, reducing thermal resistance.
4Adaptability or versatility
If multiple parts are used to构成 heat exchange bundle, then functionality is achieved, but manufacturing complexity increases
Solution Approach 1:
The invention combines multiple functions into the hollow elements themselves. The hollow elements provide fluid flow channels, the protrusions provide both heat exchange surface area and connection means for joining elements. This merging of functions into fewer components reduces manufacturing complexity compared to producing separate fins, connection pieces, and hollow elements as distinct parts.
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 improves heat exchange efficiency, reduces thermal resistance, and simplifies assembly while maintaining mechanical strength, resulting in a cost-effective and efficient heat exchanger with improved thermal performance.
Implementation Method 1
Each hollow element (31) forms at least one channel (35) inside which a first heat transfer fluid (F1) is intended to circulate... allowing heat exchange between the first F1 and second F2 fluids
Implementation Method 2
a first heat transfer fluid (F1) is intended to circulate inside the hollow elements (31)
Implementation Method 3
a second heat transfer fluid (F2) is intended to circulate outside the hollow elements (31)... allowing heat exchange between the first F1 and second F2 fluids
Implementation Method 4
heating and compressing the stack in order to allow the mechanical connection by brazing of at least the hollow protuberances
Data Source
Figure 1~2
Figure 3A~3C
Figure 4A~5A
AI summary
The present invention relates to a heat exchanger comprising a bundle (3) for heat exchange between at least a first fluid (F1) and a second fluid (F2), the heat exchange bundle (3) being made up of at least two hollow elements (31) that are superposed and configured to respectively form a channel (35) inside of which the first fluid (F1) is intended to circulate, and to allow the circulation of the second fluid (F2) in a space (37) between the superposed hollow elements (31), at least one hollow element has a plurality of protuberances (5) extending within the space (37) for the circulation of the second fluid (F2), the protuberances (5) creating a link between two adjacent hollow elements (31), and at least a first hollow element (31a) and a second hollow element (31b) arranged facing one another are in fluid communication with one another via at least one hollow protuberance (5).