Integral drain assembly for a heat exchanger and method of forming
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Solution Overview
Problem
Heat exchangers often suffer from incomplete drainage of condensed water due to non-ideal orientation during installation, leading to corrosion and freezing damage, which limits their lifespan and functionality.
Innovation Solution
An integral drain assembly is designed with non-linear passage walls and integrally formed drain walls using additive manufacturing, ensuring that condensed liquid is routed out effectively by gravity, even in challenging installation scenarios, and a common drain manifold collects liquid from multiple sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If heat exchangers are installed in non-ideal orientations to meet installation constraints, then installation flexibility is improved, but drainage of condensed water becomes incomplete leading to corrosion and freezing damage
Solution Approach 1:
The heat exchanger is divided into multiple functional sections with individual drain assemblies for each passage. Each passage wall has its own drain wall integrally formed at the non-linear portion, allowing independent drainage of condensed water from each section. This segmentation enables complete drainage even when the overall heat exchanger is installed in non-ideal orientations.
Solution Approach 2:
The integrally formed drain walls are positioned at non-linear portions of passage walls to automatically route condensed water out of passages using gravity. The design enables the heat exchanger to self-drain without requiring external drainage systems or ideal installation orientations, making the system self-sufficient in handling condensation.
2Ease of manufacture
If traditional separate drain components are used, then ease of manufacturing individual parts is improved, but device complexity increases and drainage efficiency decreases
Solution Approach 1:
Multiple drain walls are integrally formed with the passage walls as a single unified structure. This merging of previously separate components (passage walls and drain walls) into one integrally formed assembly reduces the number of parts, simplifies the overall structure, and eliminates the need for complex assembly operations while maintaining effective drainage functionality.
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 ensures complete drainage, reducing corrosion and freezing risks, enhancing the reliability and lifespan of heat exchangers, and allowing for more flexible and cost-effective installations.
Implementation Method 1
the non-linear portion 16 shown is located at a lowest point of the passage 14 when the heat exchanger 10 is in an installed position. More specifically, the lowest point of the passage 14 is positioned where gravity will ultimately draw any condensed liquid located within the passage 14.
Data Source
AI summary
A method of forming an integral drain for a heat exchanger is provided. The method includes forming a plurality of passage walls to define a plurality of passages with an additive manufacturing process, each of the passage walls having a non-linear portion. The method also includes integrally forming a drain wall with at least one of the passage walls with the additive manufacturing process to define a drain for each of the plurality of passages, the drain wall located proximate the non-linear portion of each of the plurality of passage walls.