One-Piece Rotational-Molded Plastic Heat Exchanger Module
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Heat exchanger arrangements with parallel tubes and transverse header tubes are expensive to produce due to welding requirements, and they occupy significant space, limiting their widespread adoption.
Innovation Solution
A heat exchanger module is designed as a one-piece plastic part produced via rotational molding, allowing for a compact arrangement of multiple modules stacked vertically with secured headers, eliminating the need for individual connections and optimizing space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is used to connect parallel tubes to manifolds, then connection strength and reliability are improved, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent merges the manifolds and parallel tubes into a single integrated plastic component manufactured by rotational molding. This eliminates the need for separate welding operations to connect tubes to manifolds, thereby reducing manufacturing complexity while maintaining structural integrity through the unified design.
Solution Approach 2:
The patent replaces the mechanical welding process with a rotational molding process that creates an integrated plastic structure. The welding operation (mechanical/thermal process) is substituted by a molding process that forms the entire assembly as one piece, eliminating the need for post-assembly welding while ensuring connection reliability through the molded-in structure.
2Quantity of substance
If multiple parallel tubes are arranged with spacing, then heat transfer surface area is increased, but space occupation and manufacturing complexity increase
Solution Approach 1:
The patent combines multiple tubes and manifolds into a single rotational molded component. The spaced-apart parallel tubes are integrated with the manifolds in one manufacturing step, eliminating the need for separate assembly operations while maintaining the heat transfer surface area provided by the multiple tubes.
Solution Approach 2:
The patent transitions from assembling multiple separate components in three-dimensional space to creating a single integrated structure through rotational molding. This dimensional transformation allows the complex multi-tube manifold arrangement to be manufactured as one piece, reducing manufacturing complexity while preserving the spatial arrangement needed for heat transfer.
3Loss of energy
If metal materials are used for heat exchanger arrangements, then thermal conductivity is improved, but manufacturing cost and complexity increase due to welding requirements
Solution Approach 1:
The patent changes the material parameter from metal to plastic, accepting lower thermal conductivity in exchange for dramatically reduced manufacturing complexity. The rotational molding process enables cost-effective production of the heat exchanger assembly without welding, making the overall system more economically viable despite the material's lower thermal conductivity.
Solution Approach 2:
The patent adopts a cost-effective plastic material that can be manufactured inexpensively through rotational molding. While plastic has lower thermal conductivity than metal, the overall system cost is reduced by eliminating welding operations and using a more affordable material and manufacturing process, making the heat exchanger accessible for widespread applications.
4Ease of manufacture
If conventional plastic manufacturing processes like extrusion or injection molding are used, then production simplicity is maintained, but the ability to produce complex integrated heat exchanger structures is lost
Solution Approach 1:
The patent replaces conventional linear manufacturing processes (extrusion, injection molding) with rotational molding, which uses rotational motion to distribute material uniformly throughout the mold cavity. This substitution enables the creation of complex three-dimensional integrated structures with internal passages and external features that cannot be produced by traditional plastic manufacturing methods.
Solution Approach 2:
The patent introduces rotational motion as a new dimensional element in the manufacturing process. By rotating the mold in multiple axes during the molding process, the system can create complex integrated structures with uniform wall thickness and proper material distribution throughout the three-dimensional form, which is not achievable with conventional linear extrusion or injection molding processes.
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
This approach reduces production costs and space requirements while maintaining effective heat transfer by allowing fluid to flow through multiple layers of tubes, enhancing the heat exchanger's efficiency and aesthetics.
Implementation Method 1
A powdered plastic is introduced into the cavity and plasticized by the application of heat
Implementation Method 2
the thermoplastic material to spread across the inner wall of the mold under the influence of gravity due to the rotational movement
Implementation Method 3
the module is designed as a one-piece plastic part manufactured by rotational molding... accepts the somewhat lower thermal conductivity between the fluid inside the tubes and the fluid surrounding the tubes
Data Source
Figure 1~2
Figure 3~5
Figure 6
AI summary
The invention relates to a heat exchanger arrangement comprising pipes (2) which are arranged in a module (1) parallel at a distance from each other and through which a fluid can flow, said pipes running between two transversal manifolds (3, 4) through which the fluid can also flow, at least one of the manifolds (3, 4) having at least one connection (6) for inflow or outflow of the fluid. The heat exchanger arrangement can be easily and inexpensively constructed, due to the design of the module (1) as a one-piece part made of plastics, and should preferably be produced using rotational moulding.