Printed Circuit Heat Exchanger with 3D Zigzag Channels
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Solution Overview
Problem
Existing printed circuit heat exchangers (PCHEs) face challenges such as the need for multiple units in series to achieve sufficient heat transfer length, vulnerability to clogging, structural integrity issues with high-pressure headers, and potential freezing of fluids in cryogenic environments, which affects performance and increases production costs.
Innovation Solution
A PCHE design featuring zigzag-shaped flow channels with overlapping sections, alternately stacked bonding plates, and strategically positioned high-pressure headers to enhance heat transfer efficiency, maintain performance despite clogging, and prevent freezing, while simplifying configuration and reducing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If straight or zigzag flow channels are used in PCHE, then manufacturing is simplified, but heat transfer length is insufficient requiring multiple units in series
Solution Approach 1:
The patent transitions from traditional 2D planar flow channels to 3D spatial flow channels that extend in multiple dimensions. The flow channels are designed to move not only in the plane of the plate but also in the thickness direction, creating a three-dimensional heat transfer path that increases effective heat transfer length without requiring additional plate stacks.
Solution Approach 2:
The patent implements nested flow channel structures where flow channels are positioned within and between bonding plates in a hierarchical arrangement. The 3D flow channels are embedded within the bonding plates and extend through multiple layers, creating a nested configuration that maximizes heat transfer length within the compact structure.
2Ease of manufacture
If traditional flow channel patterns are used, then manufacturing is easier, but the entire system fails if any flow channel is clogged
Solution Approach 1:
The patent divides the flow channel system into multiple independent 3D flow channels that are spatially separated and functionally independent. Each flow channel operates as a separate pathway, so that clogging in one channel does not affect the others. This segmentation provides redundancy and maintains system reliability even when individual channels are blocked.
Solution Approach 2:
The patent varies the spatial parameters of flow channels including their three-dimensional trajectories, diameters, and positioning within bonding plates. By changing these parameters, the design optimizes heat transfer efficiency while ensuring that no two channels follow identical paths, reducing the probability of simultaneous clogging and enhancing system robustness.
3Stress or pressure
If high-pressure headers are added to PCHE, then pressure containment is improved, but structural integrity is compromised and production cost increases
Solution Approach 1:
The patent merges the high-pressure header function directly into the bonding plate structure. Instead of adding separate header components, the bonding plates themselves are designed with integrated high-pressure flow channels and connection features, combining the heat transfer and pressure containment functions into a single integrated structure that maintains structural integrity.
Solution Approach 2:
The bonding plates are designed to serve multiple functions simultaneously: heat transfer, structural support, and high-pressure containment. The same bonding plate material and structure that provides thermal conduction also provides mechanical strength and pressure resistance, eliminating the need for separate header components and maintaining overall structural integrity.
4Power
If PCHE is used in cryogenic environment, then heat transfer efficiency is improved, but fluid freezing occurs causing operational delays
Solution Approach 1:
The patent incorporates heating elements or thermal insulation features during the manufacturing process or initial system setup to pre-condition the flow channels. This preliminary heating action prevents the formation of freezing conditions before they can occur during operation, ensuring continuous fluid flow and preventing operational delays.
Solution Approach 2:
The patent designs the system with thermal insulation layers or heating traces that act as a protective cushion against freezing. These features are built into the structure beforehand to compensate for heat loss in cryogenic environments, maintaining fluid temperature above freezing point and preventing the harmful effects of fluid solidification.
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 ensures continuous heat transfer performance even if some flow channels are clogged, maintains structural integrity, and prevents fluid freezing, thereby enhancing heat transfer efficiency and reducing operational delays and production costs.
Implementation Method 1
a first bonding plate configured to include two plates bonded to each other and a plurality of zigzag-shaped flow channels formed adjacent to each other between the two plates such that some sections of each of the plurality of flow channels overlap with adjacent flow channels
Implementation Method 2
The PCHE is manufactured by stacking a plurality of metal plates and diffusion-bonding the metal plates under vacuum high-temperature conditions
Data Source
AI summary
A printed circuit heat exchanger is provided. The printed circuit heat exchanger may include: a first bonding plate configured to include two plates bonded to each other and zigzag-shaped flow channels formed adjacent to each other between the two plates such that some sections of each of the plurality of flow channels are formed to overlap with adjacent flow channels; and a second bonding plate configured to include two plates bonded to each other and zigzag-shaped flow channels formed adjacent to each other between the two plates such that some sections of each of the plurality of flow channels are formed to overlap with adjacent flow channels, wherein the first bonding plate and the second bonding plate are alternately stacked.