Integral Fin-Plate Heat Exchanger Manifold Design
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Solution Overview
Problem
Conventional fin-plate heat exchangers are prone to thermomechanical fatigue cracking due to welding joints, are heavier than necessary, and require longer production times and higher costs due to separate manufacturing and welding of the manifold and core.
Innovation Solution
The fin-plate heat exchanger is designed as an integral piece where the manifold, core, and flanges are formed together using laminate members, eliminating the need for welding and allowing for rapid and cost-effective production through additive or subtractive manufacturing, with fins provided separately to enhance heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the manifold and core are manufactured separately and joined by welding, then the heat exchanger can be assembled from modular components, but welding joints are prone to thermomechanical fatigue cracking and reduce reliability
Solution Approach 1:
The manifold and core are merged into a single integral piece manufactured as one component using additive or subtractive manufacturing processes. This eliminates the welding joint that causes thermomechanical fatigue cracking, thereby improving reliability while maintaining ease of manufacture through modern manufacturing techniques.
2Productivity
If the manifold and core are manufactured separately and welded together, then production can follow conventional processes, but the welding process adds time and cost to production
Solution Approach 1:
The manifold and core are manufactured as a single integrated component using additive or subtractive manufacturing, eliminating the separate welding operation. This reduces production time and cost while the modular laminate member design maintains manufacturing flexibility and simplicity.
3Weight of stationary object
If the manifold, core, and flanges are formed as separate components, then assembly flexibility is maintained, but the heat exchanger weight increases and production time extends
Solution Approach 1:
The manifold, core, and flanges are merged into a single integral piece, eliminating the need for separate components and their associated joints. This reduces overall weight while the laminate member stacking approach maintains design flexibility and modular assembly benefits.
4Ease of manufacture
If conventional manufacturing methods are used with separate manifold and core production, then established processes can be utilized, but production costs are higher due to multiple manufacturing steps
Solution Approach 1:
The manifold and core are manufactured as one integrated component using additive or subtractive manufacturing, consolidating multiple manufacturing steps into a single process. This reduces production cost and improves efficiency by eliminating intermediate operations such as separate machining, assembly, and welding.
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 reliability by avoiding weld-related issues, reduces weight, and accelerates production while maintaining flexibility in heat exchanger design, making it suitable for aerospace applications.
Implementation Method 1
Separating the flow paths are separating plates that allow heat to transfer between the first and second flow paths
Implementation Method 2
The fins extend between adjacent separating plates. The fins are orientated in a direction to assist or guide fluid flow
Implementation Method 3
The integral piece comprises the separating plates, the first fluid enclosure structures, the second fluid enclosure structures, and the fin components brazed together
Data Source
Figure 1~2
Figure 3a~5
Figure 6~7
AI summary
A fin-plate heat exchanger is arranged to allow heat to be exchanged between a first fluid and a second fluid. The fin-plate heat exchanger (1) comprises: a core (100) with first flow paths (200) for the first fluid and second flow paths (300) for the second fluid; a plurality of separating plates (101); a plurality of fin components (103); a plurality of first enclosure bars (203, 204, 206); and a plurality of second enclosure bars (305, 306). The heat exchanger (1) further comprises a manifold (400) arranged in fluid communication with each of the first flow paths (200) of the core (100). The manifold (400) and the core (100) are formed as one integral piece, said integral piece comprising a stack of laminate members (101, 201, 301, 501, 502) and said fin components (103). The plurality of laminate members (101, 201, 301, 501, 502) comprise: first fluid enclosure structures (201) each including a first manifold section (202) and said first enclosure bars (203, 204, 206); second fluid enclosure structures (301) each including at least one second enclosure bar (305, 306), at least some of the of the second fluid enclosure structures (301) comprising a second manifold section (302). The plurality of laminate members (101, 201, 301, 501, 502) also comprise the plurality of separating plates (101), with each separating plate (101 comprising a third manifold section (102), and each separating plate (101) separating each first enclosure structure (201) from adjacent second enclosure structures (301). The first, second and third manifold sections (202, 302, 102) are shaped to form the manifold (400) when the plurality of laminate members (101, 201, 301, 501, 502) are stacked.