Micro-Channelled Panel Heat Exchanger Design
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Solution Overview
Problem
Conventional heat exchanger manufacturing processes are inefficient in producing complex structures with high heat transfer efficiency, particularly in creating micro-channeled systems that require precise temperature control and handling of various fluids in industrial and aerospace applications.
Innovation Solution
A micro-channeled panel heat exchange system is developed, featuring etched sheets with micro-channels for working fluids, which are diffusion bonded, brazed, or welded with a cover layer, allowing for flexible and thin designs that can be shaped into various geometries, and combined with manifolds for efficient fluid circulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional heat exchanger manufacturing processes are used, then manufacturing simplicity is maintained, but heat transfer efficiency and structural complexity are insufficient
Solution Approach 1:
The heat exchanger is divided into multiple thin planar members stacked together, each containing micro-channels. This segmentation allows for high heat transfer efficiency through increased surface area while maintaining manufacturing simplicity through standardized component fabrication and assembly
Solution Approach 2:
The invention transitions from conventional three-dimensional complex structures to thin planar two-dimensional members with micro-channels. This dimensional reduction simplifies manufacturing processes while dramatically increasing heat transfer surface area and efficiency
2Manufacturing precision
If diffusion bonding and additive manufacturing are used, then intricate internal structures are achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The heat exchanger is divided into multiple thin planar members stacked together, each containing micro-channels. This segmentation allows for high heat transfer efficiency through increased surface area while maintaining manufacturing simplicity through standardized component fabrication and assembly
Solution Approach 2:
The invention changes the manufacturing approach from complex additive processes to conventional subtractive or formative processes for creating micro-channels in thin plates. This parameter change in manufacturing methodology maintains internal structure precision while dramatically improving ease of manufacture
3Manufacturing precision
If brazing is used to combine planar members, then heat transfer efficiency is improved, but manufacturing precision and structural integrity may be compromised
Solution Approach 1:
The invention extracts the joining process from conventional brazing that requires high temperatures and complex procedures. Instead, it uses simple mechanical compression and diffusion bonding at lower temperatures, eliminating the harmful effects of brazing while maintaining structural integrity and heat transfer efficiency
Solution Approach 2:
The invention replaces thermal joining processes (brazing) with mechanical joining processes (compression and diffusion bonding). This substitution maintains structural integrity while avoiding the high temperatures and complex equipment required for brazing
4Ease of operation
If ports are provided for hermetic porting, then fluid circulation is enabled, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The manifold serves multiple functions: it distributes fluid to multiple micro-channel plates, collects fluid from all plates, provides hermetic sealing, and enables easy connection to external fluid systems. This multi-functionality reduces overall device complexity while enabling complete fluid circulation
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 system achieves high heat transfer efficiency and flexibility, enabling its use in diverse applications such as steel refineries, aerospace, and waste heat recovery, while reducing manufacturing costs through optimal material selection and enhanced heat transfer surfaces.
Implementation Method 1
A cover sheet, plate, or panel (e.g., the cover layer) is diffusion bonded, brazed or welded to the micro-channeled layer in an assembly
Implementation Method 2
A cover sheet, plate, or panel (e.g., the cover layer) is diffusion bonded, brazed or welded to the micro-channeled layer in an assembly
Implementation Method 3
A cover sheet, plate, or panel (e.g., the cover layer) is diffusion bonded, brazed or welded to the micro-channeled layer in an assembly
Implementation Method 4
Heat exchangers permit heat to be removed or added to the sample as may be desired
Data Source
AI summary
A micro-channeled panel heat exchange system is disclosed. An example embodiment includes: one or more micro-channeled panels, each micro-channeled panel having micro-channels fabricated internally within each micro-channeled panel for transfer of a working fluid, each of the one or more micro-channeled panels having a cover layer diffusion bonded or brazed to the micro-channels, each of the one or more micro-channeled panels having a thickness of no more than two millimeters, each of the one or more micro-channeled panels being twisted into a non-orthogonal shape; and one or more manifolds coupled to the one or more micro-channeled panels to circulate the working fluid through the micro-channels within each micro-channeled panel.