Modular Heat Exchanger Structure for Flexible Thermal Efficiency
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Solution Overview
Problem
Conventional heat exchangers have limitations in thermal efficiency due to the size of hollow pins required for fluid flow, leading to suboptimal utilization of combustion gases and high manufacturing costs, especially when producing small batches with non-standard design specifications.
Innovation Solution
A modular heat exchanger design featuring interconnected modular elements with hollow and solid pins, allowing for adjustable dimensions and thermal power, with hollow pins having a diamond-shaped cross-section and winding channels for improved gas flow and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If hollow pins are made with large cross-section to allow fluid circulation, then fluid flow capability is improved, but the voids between pins increase in size, causing combustion gases to pass through without adequately flowing over the pins
Solution Approach 1:
The heat exchanger is divided into multiple modular elements that can be interconnected, with each module containing optimized pin arrangements. This segmentation allows the system to achieve both adequate fluid flow paths and sufficient gas-pin interaction surface area, resolving the contradiction between fluid circulation capability and thermal efficiency.
Solution Approach 2:
The patent introduces winding channels that extend in multiple dimensions through the modular structure, allowing fluid to access pins from different spatial directions. This multi-dimensional approach enables effective heat exchange without requiring excessively large pin cross-sections that would create excessive voids.
2Adaptability or versatility
If dedicated manufacturing processes are provided for each type of heat exchanger, then design specifications are met, but manufacturing costs increase significantly, especially for small batches with nonstandard requirements
Solution Approach 1:
The patent employs universal modular elements that can be configured to meet different design specifications while using the same basic manufacturing processes. These multi-functional modules can be adapted to various applications through different interconnection patterns and arrangements, eliminating the need for dedicated manufacturing processes for each design variant and significantly reducing costs for small batches and nonstandard requirements.
Solution Approach 2:
The modular design allows the heat exchanger configuration to be dynamically adjusted by selecting and arranging different numbers and types of modular elements, enabling customization for various design specifications without requiring custom manufacturing processes for each configuration.
3Strength
If the heat exchanger is designed as a monolithic structure, then structural integrity is maintained, but the provision of internal hollow pins becomes difficult and expensive
Solution Approach 1:
The heat exchanger is segmented into multiple modular elements that can be manufactured separately with integrated hollow pins using standardized processes. These modules are then interconnected to form the complete heat exchanger, maintaining structural integrity while avoiding the difficulties and high costs of creating internal hollow pins in a monolithic structure.
Solution Approach 2:
The hollow pins are preliminarily formed as integral parts of the modular elements during the manufacturing process, rather than being created afterward in a monolithic structure. This preliminary action simplifies fabrication by allowing pins to be formed as part of the module casting or fabrication process, reducing overall manufacturing complexity and cost.
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 modular design enables flexible adaptation to various boiler dimensions and specifications, simplifies assembly, and enhances thermal efficiency by ensuring complete gas flow over pins, facilitating cost-effective large-scale manufacturing and improved safety.
Implementation Method 1
The duct for feeding the fluid to be heated, which by convection and conduction absorbs the heat carried by the combustion gases
Implementation Method 2
The duct for feeding the fluid to be heated, which by convection and conduction absorbs the heat carried by the combustion gases
Implementation Method 3
The duct for feeding the fluid to be heated, which by convection and conduction absorbs the heat carried by the combustion gases
Data Source
Figure 1~4
Figure 5~6
Figure 7~8
AI summary
A heat exchanger (1a, 1b, 1c, 1d) with highly flexible use, comprising a box-like body (2a, 2b, 2c, 2d) which delimits inside it at least one heat exchange chamber (3, 13, 23) and has at least one inlet (4) and at least one outlet (5) for the passage through the heat exchange chamber (3, 13, 23) of combustion products along a preferred path. More specifically, the box-like body (2a, 2b, 2c, 2d) defines at least partly in its side walls at least one duct for feeding a fluid to be heated and inside the heat exchange chamber (3, 13, 23) heat exchange elements (7) are provided and are associated with the supply duct in order to increase the thermal efficiency of the heat exchanger (1a, 1b, 1c, 1d). The peculiarity of the invention consists in that it comprises a plurality of distinct modular elements (8a, 8b, 8c, 8d, 9a, 9b, 9c, 9d) which are mutually interconnected in order to define the box-like body (2a, 2b, 2c, 2d). Advantageously, each modular element (8a, 8b, 8c, 8d, 9a, 9b, 9c, 9d) comprises at least one portion of the heat exchange elements (7), at least one portion of the supply duct and at least one portion of the heat exchange chamber (3, 13, 23) in order to obtain a heat exchanger (1) of differing dimensions and technical characteristics according to requirements.