Printed Circuit Heat Exchanger Channel Geometry Optimization
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Solution Overview
Problem
Printed circuit heat exchangers suffer from inefficiencies in heat transfer due to their geometry and are prone to fluid flow channel blockages, requiring costly filtration systems to maintain cleanliness.
Innovation Solution
The heat exchanger features reconfigurable fluid channels with varying cross-sectional shapes and spacings, and internal surfaces designed to induce turbulence, allowing for increased shared heat transfer lengths and improved fluid flow efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If filtration devices are installed to prevent blockages in small channels, then reliability is improved, but device complexity and cost increase
Solution Approach 1:
The patent changes the geometric parameters of the fluid channels, specifically increasing the channel size from the conventional 0.5-2mm range to larger dimensions. This parameter change fundamentally reduces the tendency for blockages without requiring additional filtration equipment, thereby improving reliability while avoiding increased device complexity
Solution Approach 2:
Instead of adding filtration devices to prevent blockages in small channels, the patent inverts the approach by designing channels that are inherently resistant to blockages through optimized geometry. The inversion lies in addressing the blockage problem through channel design rather than through protective additives
2Manufacturing precision
If chemical milling is used to create fluid channels, then manufacturing precision is improved, but the channels are prone to blockages due to small size
Solution Approach 1:
The patent applies parameter changes by optimizing the channel dimensions created through chemical milling. Rather than using the conventional small channel sizes (0.5-2mm), the patent designs channels with larger cross-sectional areas and optimized aspect ratios, maintaining manufacturing precision while significantly improving blockage resistance
Solution Approach 2:
The patent applies local quality by varying the channel geometry along their length, with different sections having optimized dimensions. The channels feature enlarged entry and exit zones compared to the intermediate sections, creating local quality variations that prevent blockages while maintaining efficient heat transfer in the intermediate portions
3Area of stationary object
If plates are stacked with alternate spacings to form heat transfer paths, then heat transfer surface area is increased, but heat transfer efficiency is reduced due to geometric inefficiencies
Solution Approach 1:
The patent applies local quality by creating non-uniform channel spacing and cross-sectional areas along the channel length. The intermediate portions have optimized dimensions for heat transfer, while end portions have enlarged areas for efficient fluid distribution and collection, creating local quality variations that enhance overall heat transfer efficiency
Solution Approach 2:
The patent transitions from traditional two-dimensional plate stacking to three-dimensional channel configurations with varying cross-sections along the flow path. This dimensional change allows for optimized heat transfer surfaces while maintaining efficient fluid flow patterns, resolving the contradiction between surface area and efficiency
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 design enhances heat transfer efficiency and reduces the risk of blockages, potentially lowering maintenance costs and improving overall performance compared to traditional printed circuit heat exchangers.
Implementation Method 1
internal surfaces designed to induce turbulence
Implementation Method 2
heat transfer only takes place between these adjacent plates
Data Source
AI summary
A heat exchanger includes a plurality of sets of fluid channels, each fluid channel including first and second end portions and an intermediate portion between the first and second end portions. The first end portions in a plane perpendicular to a direction of fluid flow in the channels have respective end perimeters which are in a first configuration, where adjacent end portions of different sets of fluid channels have a total first shared heat transfer length, this being a summation of lengths of mutually opposed perimeters of the so adjacent end portions of the different sets. The intermediate portions of the channels in a plane transverse to the direction of fluid flow have respective intermediate channel perimeters, the intermediate portions having a second configuration with a total second shared heat transfer length being a summation of lengths of mutually opposed channel perimeters of the adjacent channels of the different sets. Therefore, the total second shared heat transfer length is different to, and moreover greater than, the total first heat transfer length.