Layered Flexible Manifold for Plate-Fin Heat Exchanger Stress
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Solution Overview
Problem
Plate-fin heat exchangers face short service lives due to high thermal stresses caused by mismatches in thickness and mass between the thick manifolds and thin core matrices, leading to geometric, stiffness, and material discontinuities.
Innovation Solution
A flexible manifold design for plate-fin heat exchangers is developed, featuring additively manufactured horizontal and vertical guide vanes that provide structural support and allow for elastic deformation, reducing thermal stress and enhancing mechanical compliance through continuous, homogeneous transitions between the manifold and the heat exchanger core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If thick manifolds are used to meet pressure requirements, then pressure containment capability is improved, but thermal stress and geometric discontinuity increase
Solution Approach 1:
The patent employs thin-walled manifold designs with integrated flexible bellows that can elastically deform to accommodate thermal expansion and contraction. This flexible membrane approach allows the manifold to maintain pressure containment while reducing thickness and mass discontinuities, thereby decreasing thermal stress and extending service life.
Solution Approach 2:
The patent changes the physical parameters of the manifold by integrating flexible bellows with varying expansion ratios and wall thicknesses. This allows the manifold to dynamically adjust its structural properties in response to thermal and pressure conditions, optimizing both pressure containment and thermal stress resistance.
2Stress or pressure
If thick manifolds are used to meet pressure requirements, then pressure containment capability is improved, but mass and material discontinuity increase
Solution Approach 1:
The patent replaces thick rigid manifolds with thin-walled flexible structures that incorporate bellows. These flexible membranes provide sufficient pressure containment through elastic deformation rather than relying on thick walls, significantly reducing manifold mass and eliminating material discontinuities with the heat exchanger core.
3Strength
If rigid manifold connections are used, then structural strength is improved, but thermal stress increases
Solution Approach 1:
The patent transitions from static rigid manifold connections to dynamic flexible connections with integrated bellows. These flexible manifolds can elastically deform in response to thermal expansion and contraction, maintaining structural integrity while accommodating thermal movements, thereby improving thermal robustness without sacrificing strength.
Solution Approach 2:
The patent uses flexible bellows-integrated manifolds that act as compliant connections between the heat exchanger core and external piping. These flexible membranes provide the necessary structural strength while allowing thermal movement, eliminating the thermal stress problems associated with rigid connections.
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 flexible manifold design improves thermal robustness and mechanical compliance, enabling the heat exchanger to withstand temperature and pressure changes, thereby extending its service life and reducing material discontinuities.
Implementation Method 1
A flexible manifold adapted for use on a plate-fin heat exchanger core... allowing for elastic deformation, reducing thermal stress
Data Source
Figure 1A~1B
Figure 2
Figure 3A~3B
AI summary
A flexible manifold (14,16) adapted for use on a plate-fin heat exchanger core (12), the flexible manifold comprising a plurality of individual layers (136), each individual layer defining a lower floor, an upper floor, and two side walls. Each of the plurality of individual layers is adapted to channel a flow of a medium therethrough, each of the plurality of individual layers includes a plurality of vertical members (132), each of the plurality of vertical members extends vertically from the lower floor to the upper floor of the respective individual layer, and each of the plurality of vertical members is configured to provide structural support for the respective individual layer. The vertical members can be vertical guide vanes and/or vertical columns having a round and/or hydrofoil cross-sectional shape.