Asymmetric Plate Heat Exchanger Channels for Lower Pressure Drop
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Solution Overview
Problem
Modern plate heat exchangers with herringbone patterns face issues such as material distortion, high pressure drop, uneven fluid flow rates, reduced heat transfer efficiency, and mechanical instability due to thick metal sheets and uneven solder distribution, especially when handling fluids with different properties.
Innovation Solution
Designing heat exchanger plates with alternating patterns of different indentation densities and shapes to create distinct fluid channels, allowing for tailored mechanical stability and fluid flow characteristics, reducing pressure drop and enhancing heat transfer efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thick metal sheets are used to withstand high pressures, then pressure resistance is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent changes the geometric parameters of the plate structure by introducing specific indentation patterns (ridges and valleys) that alter the mechanical properties of the plate. These geometric modifications enable thinner plates to achieve the required pressure resistance without increasing manufacturing complexity
Solution Approach 2:
The patent employs curved surfaces through the indentation pattern, where ridges and valleys create non-planar geometries that enhance structural strength. The curved surfaces distribute stress more effectively, allowing thinner plates to withstand high pressures
2Area of stationary object
If herringbone pattern indentations are pressed into metal sheets, then heat exchange surface area is improved, but material flow becomes unfavorable and cracks may appear
Solution Approach 1:
The patent modifies the indentation parameters by adjusting ridge angles, valley depths, and spacing to optimize both heat exchange area and material flow during pressing. The specific geometric parameters are chosen to minimize stress concentrations that cause cracking
Solution Approach 2:
The patent applies different indentation characteristics in different regions of the plate. The ridge and valley dimensions are locally optimized to accommodate varying material flow requirements across the plate surface, preventing crack formation in high-stress areas
3Strength
If copper or copper alloy solder is used in fully brazed joints, then joint strength is improved, but solder distribution becomes uneven and surface area for soldering is reduced
Solution Approach 1:
The patent creates localized zones with different indentation characteristics that control solder flow and distribution. Specific ridge and valley configurations are designed to trap and distribute solder uniformly across joint areas, maximizing the effective solder surface area
Solution Approach 2:
The indentation pattern acts as an intermediary structure that mediates solder distribution. The ridges and valleys serve as channels and reservoirs that guide copper solder to achieve uniform distribution across the joint surfaces
4Power
If fluid is forced to flow over ridges and down into valleys in herringbone pattern, then heat transfer rate is improved where flow rate is high, but pressure drop increases and heat transfer rate decreases where flow rate is low
Solution Approach 1:
The patent optimizes the geometric parameters of ridges and valleys to control fluid flow characteristics. By adjusting ridge angles, heights, and spacing, the patent achieves a balance between generating sufficient turbulence for heat transfer and minimizing pressure drop
Solution Approach 2:
The patent applies partial herringbone patterns or combines them with straight channel sections. This allows heat transfer enhancement in specific regions while maintaining lower pressure drop in other regions, achieving an optimal balance
5Power
If two-phase fluid flows through herringbone pattern heat exchanger, then heat exchange occurs, but gas forces liquid away from contact with plates reducing wetting and heat transfer rate
Solution Approach 1:
The patent creates specific local geometries in the indentation pattern that promote liquid retention. Certain valley configurations and ridge angles are designed to counteract gas forces and maintain liquid contact with the plate surfaces in two-phase flow conditions
6Ease of manufacture
If indentations are made with equal number on both sides of the plate, then manufacturing simplicity is improved, but mechanical stability and fluid flow optimization are compromised
Solution Approach 1:
The patent employs asymmetric indentation patterns where the number, size, or distribution of ridges and valleys differs between the two sides of the plate. This asymmetry is specifically designed to optimize mechanical stability under pressure differentials and to control fluid flow characteristics for enhanced heat transfer performance
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 solution provides improved mechanical stability, reduced pressure drop, and increased heat transfer efficiency by optimizing fluid flow and channel design, while allowing for thinner metal usage and reduced manufacturing costs.
Implementation Method 1
the resulting heat exchanger pack comprises a pattern of fluid channels through which the respective two fluids can flow and exchange their thermal energy
Implementation Method 2
A fluid which is made to flow through a heat exchanger with a herringbone pattern is forced to flow over the ridges and down into the valleys
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a plate heat exchanger (9) with a plurality of heat exchanger plates (1, 13), each comprising at least one section showing indentations (2, 3, 14, 15), intended to be placed against corresponding indentations (2, 3, 14, 15) of a heat exchanger plate (1, 13) of a corresponding design. The heat exchanger (9) has a first type of indentations (2, 14) and a second type of indentations (3, 15), wherein the number of said first type of indentations (2, 14) and said second type of indentations (3, 15) are differing.