Heat Exchanger Mount Assembly for Thermal Expansion and Leak Control

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Solution Overview

Problem

Conventional heat exchangers used in the oil and gas industry, particularly in fracturing operations, face issues with weight, noise pollution, ineffective cooling due to temperature gradients, structural integrity due to thermal expansion, and leaks at welds, which affect their performance and reliability.

Innovation Solution

A heat exchanger unit with a frame and baffles configured to improve airflow, reduce noise through sound-absorbing materials, and enhance structural integrity by using flexible mount assemblies and v-groove welds to prevent braze material flow and leakage, while accommodating thermal expansion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If conventional heat exchangers are used in fracturing operations, then cooling function is provided, but weight is excessive and noise pollution is generated

Engineering Contradiction:

Improvenoise pollutionVSAvoidcooling efficiency

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The patent applies porous sound-absorbing materials within the heat exchanger structure to reduce noise pollution from the fracturing operation while maintaining the cooling function through the heat exchange surfaces

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent nests multiple functional elements within the heat exchanger including sound-absorbing materials, flexible mount assemblies, and v-groove weld structures to achieve both noise reduction and effective cooling in a compact configuration

Inventive Principle:

Principle #7Nested doll (Nesting)

2Productivity

If conventional heat exchangers are used, then cooling is provided, but temperature gradients cause ineffective cooling

Engineering Contradiction:

Improvecooling efficiencyVSAvoidtemperature gradient

Core Design Contradiction:

ProductivityVSTemperature

Solution Approach 1:

The patent implements local quality variations in the heat exchanger design, including varying baffle configurations and airflow path characteristics to optimize heat transfer at different locations and reduce the impact of temperature gradients on overall cooling efficiency

Inventive Principle:

Principle #3Local quality

3Stability of the object's composition

If conventional heat exchangers are used, then cooling function is provided, but thermal expansion causes structural integrity issues

Engineering Contradiction:

Improvestructural integrityVSAvoidthermal expansion

Core Design Contradiction:

Stability of the object's compositionVSTemperature

Solution Approach 1:

The patent explicitly addresses thermal expansion by incorporating flexible mount assemblies that allow the heat exchanger to expand and contract with temperature changes while maintaining structural integrity and proper positioning within the system

Inventive Principle:

Principle #37Thermal expansion

4Reliability

If conventional heat exchangers are used, then cooling is provided, but leaks occur at welds

Engineering Contradiction:

Improveleak preventionVSAvoidwelding complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies v-groove welds at specific critical locations where leaks are most likely to occur, providing enhanced sealing quality at these key joints while maintaining ease of manufacture through standardized welding procedures at these predetermined locations

Inventive Principle:

Principle #3Local quality

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 results in a lighter, quieter, and more efficient cooling system with improved structural integrity, reducing noise emissions and increasing airflow while preventing leaks and braze material flow, thus enhancing the heat exchanger's performance and reliability.

Implementation Method 1

reduce noise through sound-absorbing materials

Methodology Applied

Scientific EffectAcoustic absorption: Acoustic Absorption

Implementation Method 2

baffles configured to improve airflow

Methodology Applied

Scientific EffectFlow direction control:

Implementation Method 3

accommodating thermal expansion

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 4

v-groove welds to prevent braze material flow and leakage

Methodology Applied

Scientific EffectWelding: Welding

Implementation Method 5

heat exchanger unit with a frame and baffles configured to improve airflow

Methodology Applied

Scientific EffectHeat transfer: Heat Exchanger

Data Source

PatentUS10520220B2Heat exchanger unit

Publication Date: 2019.12.31 FORUM US INC

AI summary

Embodiments of the disclosure pertain to a heat exchanger unit that includes a frame and at least one cooler. The cooler is associated with a respective side region of the heat exchanger unit, and the cooler has an outer surface and an inner surface. The unit can include a mount assembly for coupling the cooler to the frame. The mount assembly includes an elongated fastening member; a rigid outer ring; a rigid inner ring; and a deformable ring disposed between the rigid outer ring and the inner outer ring. The cooler may have a core end mass greater than a tank end mass.