Heat Exchanger Plate with Variable Radius Collars
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Intermittent operation of coolant systems in vehicles leads to large temperature fluctuations, causing thermal stresses and fatigue issues in heat exchanger components, particularly at plate assemblies and fin connections, which reduces durability and fatigue life.
Innovation Solution
A plate and fin assembly design for heat exchangers featuring cups with variable radii collars, guiding and restricting protrusions, and cutout portions in fins to minimize thermal stresses and enhance structural support, allowing for improved thermal expansion management and increased fatigue life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If intermittent operation of coolant systems is implemented to improve fuel efficiency and control air temperature, then energy usage is minimized and air temperature is controlled, but large temperature fluctuations cause thermal stresses and fatigue issues in heat exchanger components
Solution Approach 1:
The fin design implements local quality by providing different fin configurations in different regions of the plate assembly. Full-length fins are provided at the air inlet side and intermediate regions where thermal stresses are highest, while shorter fins are used in other areas. This localized reinforcement provides enhanced structural support exactly where needed to withstand thermal expansion and contraction during intermittent operation.
Solution Approach 2:
The fin structure is segmented into different types: full-length fins that extend along the entire length of the plate assembly, intermediate-length fins, and shorter fins. This segmentation allows each fin type to serve specific functions - full-length fins provide maximum structural support at critical stress regions, while shorter fins reduce weight and material usage in less critical areas.
2Strength
If fins are extended along the entire length of plate assemblies to provide structural support, then thermal stress resistance is improved, but manufacturing complexity and material usage increase
Solution Approach 1:
Instead of uniformly extending fins along the entire plate assembly, the invention applies full-length fins only at specific locations where thermal stresses are highest - namely the air inlet side and intermediate regions. This localized approach provides necessary structural support while avoiding the increased complexity and material usage that would result from full-length fins throughout the entire assembly.
3Stability of the object's composition
If plate assemblies are rigidly connected to accommodate minimal thermal expansion, then structural stability is maintained, but fatigue life is reduced due to inability to accommodate thermal fluctuations
Solution Approach 1:
The fin structures act as flexible elements that can accommodate thermal expansion and contraction of the plate assemblies during intermittent operation. The fins provide a degree of compliance that allows the rigid plate assemblies to move slightly with thermal fluctuations without developing excessive stresses, thereby extending fatigue life while maintaining overall structural stability.
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 reduces thermal stresses by 15% compared to constant radius collars and maximizes structural integrity and heat transfer efficiency, enhancing the durability and performance of heat exchangers during intermittent coolant system operation.
Implementation Method 1
Heat exchangers are employed in the coolant system to transfer heat between the air flowing through the engine air system and the coolant flowing through the coolant system
Implementation Method 2
The heat exchangers include a heat exchange core with plate assemblies interposed between fins
Implementation Method 3
the plate assemblies are connected to each other and are not suited to accommodate large variations in thermal expansion and contraction caused by the temperature fluctuations
Data Source
AI summary
A plate for a heat exchanger includes a substantially planar body having a first end, a second end opposing the first end, a fluid surface, and an outer surface. A first cup extends from the outer surface of the body adjacent the first end of the body. A second cup extends from the outer surface of the body and is spaced from the second end of the body.