Heat Exchanger With Segmented Channels For Enhanced Heat Transfer
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Solution Overview
Problem
Conventional heat exchangers face inefficiencies in heat transfer due to the limited surface area and fluid flow dynamics, particularly in the arrangement and shape of channels, which restricts effective heat exchange between fluids.
Innovation Solution
The heat exchanger features alternating patterns of first and second fluid channels with end portions that extend beyond the first channels, decreasing in cross-sectional area or shape, allowing for enhanced fluid flow and turbulence, and is manufactured using additive methods like 3D printing to optimize heat transfer surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional heat exchanger channels are used with uniform length and cross-section, then manufacturing is simple, but heat transfer surface area is limited and heat exchange efficiency is reduced
Solution Approach 1:
The heat exchanger divides the fluid channels into multiple segments with different lengths. Second fluid channels are segmented into a first portion (within the bounding box) and a second portion (extending beyond), allowing optimized heat transfer paths while maintaining manageable manufacturing complexity through modular segmentation.
Solution Approach 2:
The patent extends second fluid channels beyond the bounding box defined by first fluid channels, utilizing the third dimension (length extension) to increase heat transfer surface area. This dimensional expansion allows additional heat exchange opportunities without compromising the compact arrangement of the core structure.
2Area of stationary object
If fluid channels are arranged in alternating pattern with extended end portions, then primary heat transfer surfaces are increased, but fluid flow paths become more complex
Solution Approach 1:
The patent applies different channel configurations to different locations: first fluid channels maintain uniform length for straightforward flow, while second fluid channels extend beyond the bounding box at specific locations to maximize heat transfer surface area. This localized differentiation optimizes heat transfer without uniformly complicating the entire flow system.
Solution Approach 2:
The extended portions of second fluid channels are positioned to receive first fluid that flows around them before entering the main heat exchange zone. This preliminary interaction with extended channel portions prepares the fluids for more effective heat exchange in the primary alternating pattern sections.
3Productivity
If second fluid channels extend beyond first fluid channels, then heat transfer efficiency is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent employs additive manufacturing technology that enables dynamic adjustment of channel geometries during the manufacturing process. This allows precise control over the extended portions of second fluid channels, accommodating the increased geometric complexity while maintaining manufacturing feasibility through layer-by-layer construction with inherent tolerance flexibility.
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
This configuration increases the primary heat transfer surfaces and induces fluid turbulence, leading to improved heat exchange efficiency between fluids, enhancing temperature differential reduction.
Implementation Method 1
heat exchange occurs between the fluids across the wall, and secondary heat exchange surfaces, wherein heat is conducted along a member to another location to be cooled
Implementation Method 2
induces fluid turbulence, which aids in the heat exchange
Data Source
AI summary
A heat exchanger for exchanging heat between first and second fluids, comprising first fluid channels extending in a longitudinal direction for carrying a first fluid, and second fluid channels extending in the longitudinal direction for carrying a second fluid, wherein the first and second fluid channels are arranged in an alternating pattern such that each of a plurality of the first channels is located laterally between second channels and each of a plurality of second channels is located laterally between first channels, and wherein the second fluid channels extend longitudinally beyond ends of the first fluid channels, and have ends that decrease in cross section such that the first fluid is able to pass around and between the ends of the second channels.