Modular Plastic Heat Exchanger for Corrosive Fluids
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Solution Overview
Problem
Existing heat exchangers face challenges such as thick walls limiting heat transfer, laborious assembly processes, fouling, and corrosion issues, particularly in industrial-scale applications with corrosive fluids like seawater.
Innovation Solution
A heat exchanger design featuring a matrix configuration of plastic modules with integral connectors for self-supporting stability, allowing low wall thickness and easy assembly, using a snap or slide fit mechanism, and made from materials like thermoplastic for reduced fouling and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thick walls are used in heat exchanger elements, then structural strength and stability are improved, but heat transfer efficiency deteriorates due to increased thermal resistance
Solution Approach 1:
The heat exchanger is divided into multiple modular elements that can be assembled together. Each element contains a limited number of tubes (e.g., 5-10 tubes per element), allowing the use of thinner tube walls while maintaining overall structural integrity through the modular configuration and supporting structures.
Solution Approach 2:
The patent employs composite construction with tubes made from materials optimized for heat transfer (with thinner walls) combined with supporting structures and connecting elements that provide the necessary mechanical strength and stability, separating the thermal function from the structural support function.
2Reliability
If multiple heat exchanger elements are assembled into a large block, then heat exchange capacity is improved, but assembly complexity and labor requirements increase significantly
Solution Approach 1:
The heat exchanger is segmented into standardized modular elements that can be manufactured independently and then assembled. Each module contains a defined configuration of tubes and connecting webs, allowing for systematic assembly of larger heat exchange blocks without proportionally increasing complexity.
Solution Approach 2:
Multiple functional components (tubes, connecting webs, support structures) are merged into integrated modular elements that can be manufactured as single pieces or pre-assembled units, reducing the number of separate assembly operations required when building larger heat exchanger blocks.
3Reliability
If metal materials are used for heat exchanger tubes, then heat transfer efficiency is improved, but corrosion and fouling problems worsen when handling corrosive fluids
Solution Approach 1:
The material selection shifts from traditional metals to plastic materials (such as polypropylene, polyethylene, PVDF, or PTFE), changing the chemical resistance parameters while accepting lower thermal conductivity. This material substitution resolves the corrosion and fouling issues with corrosive fluids like seawater.
Solution Approach 2:
The patent may employ composite construction where plastic tubes (resistant to corrosion) are combined with metal supporting structures or connecting elements, separating the fluid-contact function (requiring corrosion resistance) from the structural support function (where metal provides strength).
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 achieves high heat transfer efficiency with a low material usage, reducing manufacturing costs and maintaining stability, while being easy to manufacture and disassemble, and effectively handling corrosive fluids without significant fouling or corrosion.
Implementation Method 1
heat exchange between fluids flowing through the heat exchanger modules, wherein the modules are arranged in a matrix configuration that comprises at least two columns of longitudinal tubes and at least two rows of longitudinal tubes
Data Source
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AI summary
The invention relates to a heat exchanger (10) for heat exchange between fluids, comprising a housing (12) having an inlet (20, 27) and an outlet (26, 28) for each fluid, the inlet (20, 27) and outlet (26, 28) for each fluid being connected to one another by a flow path (38, 58), the flow path (38) of a first fluid comprising multiple heat exchange modules (60) comprising at least one longitudinal hollow tube (36), wherein the modules (60) are arranged in a matrix configuration that comprises at least two columns of longitudinal tubes (36) and at least two rows of longitudinal tubes (36), and wherein a module (60) is provided with at least one connector (50) for connecting to a co-operating connector of an adjacent module, such that the space (56) enclosed between adjacent modules (60) defines a flow path (58) for a second fluid, parallel to the flow path (38) for the first fluid.