Heat Exchanger With Variable Geometry Flow Openings
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Solution Overview
Problem
Conventional heat exchangers constructed from flat sheet metal dividing plates and corrugated fins have limitations in thermal efficiency due to manufacturing simplicity, which restricts the ability to control performance effectively.
Innovation Solution
A heat exchanger design featuring flow openings of varying shapes and sizes arranged in a checkerboard pattern, with channel tubes inserted through aligned openings to form channels that change in area and shape along the body, allowing for enhanced control of flow and thermal efficiency, and a manufacturing method involving stamping and brazing of sheets to form the heat exchanger structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional flat sheet metal dividing plates and corrugated fins are used, then manufacturing simplicity is maintained, but thermal efficiency and performance control are limited
Solution Approach 1:
The patent applies parameter changes by transitioning from conventional flat sheets with uniform corrugations to stamped sheets with variable geometry flow openings. The flow openings can be circular, polygonal, or other shapes with varying sizes, allowing precise control of flow area and thermal efficiency while maintaining manufacturing simplicity through stamping processes.
Solution Approach 2:
The patent implements local quality by creating non-uniform flow distribution through strategically designed flow openings of different shapes and sizes at different locations. This allows different regions of the heat exchanger to have optimized flow characteristics, improving overall thermal efficiency while maintaining ease of manufacture through stamping.
2Ease of operation
If uniform flow openings are used throughout the heat exchanger, then manufacturing is simpler, but flow control and pressure drop management are limited
Solution Approach 1:
The patent uses parameter changes by varying the size, shape, and distribution of flow openings throughout the heat exchanger. Flow openings can be circular, polygonal, or other shapes with different areas, enabling precise control of flow distribution and pressure drop while maintaining relatively simple manufacturing through stamping processes.
3Manufacturing precision
If complex multi-layer sandwich cores with uniform geometry are used, then manufacturing is straightforward, but weight reduction and thermal performance optimization are limited
Solution Approach 1:
The patent applies parameter changes by using stamped sheets with variable geometry flow openings instead of uniform corrugated fins. The flow openings can be circular, polygonal, or other shapes with varying sizes, allowing optimization of thermal performance and weight while maintaining manufacturing simplicity through stamping processes.
Solution Approach 2:
The patent implements composite materials by combining stamped metal sheets with selective flow opening patterns to create a multi-functional core structure. The stamped sheets provide both structural support and optimized flow distribution, achieving weight reduction and thermal performance improvement while maintaining manufacturing simplicity.
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 design enhances thermal efficiency, reduces weight, and allows for better control of thermal stresses and pressure drop, enabling improved heat transfer and integration with systems while maintaining a simple and cost-effective manufacturing process.
Implementation Method 1
a heat exchanger includes a body, a plurality of first flow channels defined in the body, and a plurality of second flow channels defined in the body
Implementation Method 2
The method can further include joining the first flow tubes together at one or both ends to form an inlet header and/or outlet header
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 2
AI summary
A method for manufacturing a heat exchanger includes aligning a plurality of first flow openings (303) and second flow openings (305) defined in a plurality of sheets (301a), and attaching the plurality of sheets together to form a plurality of first flow channels (103) from the aligned first flow openings and a plurality of second flow channels (105) from the aligned second flow openings. Attaching the plurality of sheets together includes brazing the sheets together.