Monoblock Heat Exchanger Channels for Turbulence and Pressure Resistance
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Solution Overview
Problem
Existing heat exchangers face challenges in generating turbulent flow while maintaining high pressure resistance and preventing media mixing, which are essential for efficient heat transfer and pressure endurance.
Innovation Solution
A one-piece monoblock heat exchanger design featuring intersecting straight channels with parallelogram-shaped support pillars, ensuring turbulent flow and high pressure resistance, and eliminating the need for solder joints or seals by using side wall openings for channel access and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If solder joints are used to connect plates and turbulators, then the heat exchanger can be assembled from separate components, but the solder joints can become defective causing media mixing or contamination
Solution Approach 1:
The patent merges multiple separate components (plates, turbulators, seals) into a single monoblock element manufactured by selective laser melting. This eliminates solder joints and seals entirely, resolving the reliability issue while maintaining manufacturing feasibility through additive manufacturing technology.
2Device complexity
If blind holes are used for channels in a monoblock cooling plate, then the structure is simplified, but the flow of fluid will be essentially laminar
Solution Approach 1:
The patent replaces straight blind hole channels with zigzag or sawtooth pattern channels that follow a curved, non-linear path through the monoblock. This increases fluid turbulence and heat transfer efficiency while maintaining the simplified monoblock structure, resolving the contradiction between structural simplicity and heat transfer performance.
3Device complexity
If channels are open at both ends with plugs, then the monoblock structure is maintained, but the pressure resistance is relatively low
Solution Approach 1:
The patent transitions from 2D surface-mounted plugs to 3D integrated support pillars that extend throughout the monoblock structure. These pillars are formed by the intersecting channel system itself, creating a three-dimensional load-bearing framework that significantly enhances pressure resistance while maintaining the open-channel configuration.
4Productivity
If intersecting channels are created in a monoblock, then turbulent flow can be generated, but the pressure resistance may be compromised
Solution Approach 1:
The patent resolves this contradiction by creating support pillars that extend in the third dimension through the monoblock, forming a 3D lattice structure at channel intersections. This three-dimensional reinforcement maintains turbulent flow paths while providing sufficient structural strength to withstand operating pressures.
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 effectively generates turbulent flow, achieves high pressure resistance up to 150 bar, and prevents media mixing, enhancing heat transfer efficiency and system reliability.
Implementation Method 1
The flow chamber has at least partially a heat-permeable wall, so that the medium can absorb or release thermal energy or heat energy through this wall
Implementation Method 2
The invention is based on the object of providing a generic device in which a turbulent flow of the medium is generated very effectively
Data Source
Figure 1
Figure 2a~2b
Figure 3~8
AI summary
The invention relates to a device, comprising at least one flow chamber (20') having an inlet opening and an outlet opening, said flow chamber being provided for the flow of a medium therethrough. The flow chamber (20') is arranged in a single-piece block element (2) and is at least partly delimited by a transcalent wall in order to effect absorption or release of thermal energy through the wall by means of the medium. The at least one flow chamber (20') is formed in the block element (2) from a plurality of first channels (22) spaced apart from each other, which extend straight and parallel to each other, and a plurality of second channels (23) spaced apart from each other, which extend straight and parallel to each other, the first and the second channels (22, 23) each having two ends and being closed at least at one (27) of the two ends. The second channels (23) are arranged at an angle to the first channels (22), the first channels and the second channels thus crossing. Support pillars (21) having a parallelogram-shaped cross-section are present within each flow chamber (20') between the crossing points of two adjacent first channels (22) and two adjacent second channels (23). A turbulent flow of the medium can be produced very effectively in the device according to the invention.