Layered Heat Exchanger Plates for Coolant Separation and Leak Detection
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Solution Overview
Problem
Existing heat exchangers face inefficiencies due to dead zones and media mixing when different cooling media are coupled, leading to reduced heat exchange efficiency and durability issues.
Innovation Solution
A heat exchanger design with independent flow channels for multiple cooling media, using overlapping guides in heat-exchanging plates to prevent mixing and enhance coupling, with aligned through holes forming a single discharge path for leak detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple cooling media are coupled in existing heat exchangers, then heat exchange capability is enhanced, but dead zones are formed and media mixing occurs reducing efficiency
Solution Approach 1:
The heat exchanger is segmented into multiple independent heat-exchanging plates, each with separate flow channels for different cooling media. This segmentation prevents dead zones and media mixing while maintaining enhanced heat exchange capability across multiple plates.
Solution Approach 2:
Each heat-exchanging plate is designed with locally optimized flow channels that ensure complete media circulation without dead zones. The guides and through-holes are positioned to create uniform flow distribution across each plate's surface, preventing stagnation and mixing.
2Productivity
If cooling media are circulated through coupled plates, then heat exchange is performed, but coupling capability and durability are reduced
Solution Approach 1:
The guides are designed with nested structures where through-holes in one plate align with through-holes in adjacent plates, creating interlocking flow paths. This nesting enhances coupling durability while maintaining heat exchange performance.
Solution Approach 2:
Multiple heat-exchanging plates are combined in a stacked configuration with alternating flow channels. This merging of multiple plates creates a durable coupled structure that maintains reliable sealing and coupling while enabling continuous heat exchange.
3Area of stationary object
If heat-exchanging plates are layered to increase contact area, then heat exchange efficiency is improved, but media mixing occurs
Solution Approach 1:
The layered structure is segmented into alternating flow channels for different cooling media. Each plate type has dedicated channels that prevent mixing while maximizing contact area through the layered arrangement.
Solution Approach 2:
The guides act as intermediaries that separate and direct different cooling media through alternating channels in the layered plates. This mediation prevents media mixing while maintaining efficient heat exchange across the increased contact area.
4Productivity
If independent flow channels are created for multiple cooling media, then media mixing is prevented, but structural complexity increases
Solution Approach 1:
The guides serve multiple functions: they define flow channels, provide structural support for coupling plates, and create sealing surfaces. This multi-functionality reduces overall structural complexity while maintaining independent flow channels for different cooling media.
Solution Approach 2:
The flow channel definition and plate coupling functions are merged into the guide structure. This integration simplifies the overall design by combining what could be separate components into a unified guide element that performs multiple tasks.
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
Improves heat exchange efficiency, durability, and leak detection by ensuring separate circulation paths and increased contact area, while preventing media mixing and enhancing rigidity.
Implementation Method 1
a heat exchanger capable of performing heat exchange between different kinds of cooling media
Data Source
AI summary
A heat exchanger is disclosed. Different cooling media are circulated in respective independent flow channels between the first heat-exchanging plate and the second heat-exchanging plate so as to perform heat exchange while preventing mixing between the different cooling media. A first guide of the first heat-exchanging plate and a second guide of the second heat-exchanging plate are layered to form an overlapping structure, and thus coupling capability and durability are improved when the first heat-exchanging plate and the second heat-exchanging plate are welded to each other. A discharge path is provided in order to detect internal leakage after welding between the first heat-exchanging plate and the second heat-exchanging plate, thereby making it possible to determine that there is malfunction in the heat exchanger based on the cooling media exposed from the discharge path when the cooling media leaks due to an internal defect.