Method for manufacturing a series of at least one first and one second heat exchangers
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Solution Overview
Problem
Custom manufacturing of brazed plate heat exchangers for air separation units is costly and time-consuming due to the need for variable designs to accommodate different pressure and flow rate requirements, while standardized matrices either oversupply or undersupply matrices, leading to inefficiencies and increased costs.
Innovation Solution
A method for manufacturing a series of heat exchangers with adaptable fluid distribution boxes that can be configured after matrix production, allowing for variable assignment of passages to fluids, using standardized matrices that can be prefabricated and assembled with partitioning means to adjust the number of openings for each fluid, maintaining consistent interfaces with the rest of the installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If custom manufacturing is used to adapt to variable pressure and flow rate requirements, then adaptability is improved, but manufacturing time and cost increase
Solution Approach 1:
The heat exchanger is divided into standardized matrices that can be manufactured independently in advance, and fluid distribution boxes that are configured separately according to specific requirements. This segmentation allows the matrices to be produced in bulk while the distribution boxes are customized, reducing overall manufacturing time while maintaining adaptability.
Solution Approach 2:
The standardized matrices are manufactured in advance before the final configuration is determined. This preliminary production of core components enables economies of scale and reduces lead time when custom orders come in, as only the fluid distribution boxes need to be customized rather than the entire heat exchanger.
2Adaptability or versatility
If custom manufacturing is used to meet specific project requirements, then adaptability is improved, but manufacturing cost increases
Solution Approach 1:
By separating the heat exchanger into standardized matrices and customizable fluid distribution boxes, the patent enables bulk production of matrices at lower cost while only customizing the distribution boxes for each specific application, thereby reducing overall manufacturing cost while maintaining adaptability.
Solution Approach 2:
The standardized matrices are designed to be universal components that can be used across multiple different heat exchanger configurations. This universality allows the same matrix design to serve multiple customers and applications, reducing per-unit manufacturing cost through economies of scale while still meeting specific project requirements through customized distribution boxes.
3Productivity
If standardized matrices are used to reduce manufacturing time, then productivity is improved, but adaptability deteriorates due to oversupply or undersupply
Solution Approach 1:
The patent segments the heat exchanger into standardized matrices for efficient bulk production and customizable fluid distribution boxes for specific configuration. This allows standardized matrices to be manufactured in advance with high productivity, while the fluid distribution boxes are then customized to match specific project requirements, combining the benefits of both standardization and customization.
Solution Approach 2:
The system allows dynamic configuration of fluid distribution boxes on standardized matrices. The number and arrangement of distribution boxes can be adjusted according to specific requirements, enabling the same standardized matrix to be adapted to different applications without re manufacturing the entire heat exchanger.
4Ease of manufacture
If fewer standardized matrices are used to reduce cost, then manufacturing cost is reduced, but energy efficiency deteriorates
Solution Approach 1:
The fluid distribution boxes can be dynamically configured to optimize the number and arrangement of passages for each specific application. This allows the heat exchanger to be precisely sized and configured to meet energy efficiency requirements without overspending on additional standardized matrices, as the distribution boxes can be adjusted to achieve optimal thermal performance.
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 approach reduces manufacturing time and costs by enabling economies of scale in producing standardized matrices, allowing for flexible configuration to meet specific project demands without degrading energy efficiency, while maintaining consistent interfaces with existing systems.
Implementation Method 1
a successive stack of laminations and corrugations, and a plurality of passages which are delimited by the stack of laminations and corrugations to allow the flow of at least a first fluid and a second fluid through the exchanger which exchange their heat with at least a third fluid
Data Source
Figure 1~2
Figure 3~4
AI summary
In a process for manufacturing a series of at least one first and one second plate and fin heat exchangers (10), several elongated fluid distribution boxes (42) are installed on the matrix, each covering only a portion of the openings (20) assigned to the first fluid (A) and the second fluid (B), each having its axis in the direction of stacking, each connected to a conduit (30,40) such that the number of openings assigned to the first fluid is different from the number of openings assigned to the first fluid, and preferably the number of openings assigned to the second fluid is different from the number of openings assigned to the second fluid, for at least the first and second exchangers in the series.