Modular Heat Exchanger Inserts for Low-Resistance Cooling Flow
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Solution Overview
Problem
Existing heat exchangers for cooling components face challenges in adaptability and efficiency, particularly in meeting diverse sizing needs and optimizing flow resistance.
Innovation Solution
A modular heat exchanger design featuring separate inserts within the housing frame, configured as wavelike sheet metal sections, with fluid-tight connections to the housing base and cover, and incorporating flow redirection elements to minimize resistance and enhance adaptability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a meandering channel is formed from a plate by removing material, then the heat exchanger can be manufactured, but it cannot be easily adapted to different sizing needs and requirements
Solution Approach 1:
The housing frame is divided into modular components: a base housing frame and separate inserts. The inserts can be independently manufactured and attached to create different channel configurations. This segmentation allows the same basic housing frame to be adapted to various sizing needs by simply changing which inserts are used, without redesigning the entire structure.
Solution Approach 2:
The housing frame is designed as a universal base structure that can accommodate multiple types of inserts with different channel configurations. A single housing frame design can serve multiple applications by combining it with different inserts, making the system multi-functional and highly adaptable to different requirements.
2Productivity
If additional components are added to guide the cooling medium, then flow resistance can be minimized, but manufacturing complexity increases
Solution Approach 1:
The flow guidance function is segmented into separate inserts that can be independently manufactured using standard sheet metal forming processes. These inserts are then attached to the housing frame, allowing the complex flow guidance geometry to be manufactured separately and assembled, which simplifies the overall manufacturing process while maintaining cooling efficiency.
Solution Approach 2:
The inserts incorporate curved and rounded geometries that guide the cooling medium flow smoothly, reducing turbulence and flow resistance. The curved surfaces are formed through standard sheet metal bending and forming processes, making them manufacturable while effectively optimizing the flow path for heat exchange efficiency.
3Reliability
If the channel extends over the entire height of the housing frame, then cooling coverage is maximized, but adaptability to different requirements is reduced
Solution Approach 1:
The vertical channel coverage is achieved through multiple inserts that can be stacked or combined in different configurations within the housing frame. Each insert can be independently designed with specific channel heights, allowing the total cooling coverage to be adjusted by selecting and combining appropriate inserts, thus maintaining both full coverage and adaptability.
Solution Approach 2:
The system allows dynamic reconfiguration of the channel structure by enabling users to select different inserts based on specific cooling requirements. The modular design permits the channel configuration to be dynamically adjusted to match different application needs while maintaining comprehensive cooling coverage through proper insert selection.
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 design allows for economical manufacturing and flexible configuration to meet various requirements, optimizing cooling medium flow and reducing resistance, thereby enhancing the heat exchanger's efficiency and adaptability.
Implementation Method 1
the at least one insert is connected to the housing base and the housing cover in a fluid-tight manner for the cooling medium... the second sections are configured in a straight line and form lateral limitations of the at least one channel... rounded arc sections that serve for flow redirection
Implementation Method 2
Heat exchanger for cooling components... heat-generating electronic or electrical components
Implementation Method 3
a meandering channel for a cooling medium arranged in a housing frame... cooling medium flow
Data Source
AI summary
A heat exchanger for cooling components. The head exchanger includes at least one meandering channel, which is arranged inside a housing, for a cooling medium, wherein the housing is formed in a sandwich-like manner with a housing base, a housing cover and a housing frame, which is arranged between the housing base and the housing cover, with the at least one channel being arranged in the region of the housing frame.