Plate Heat Exchanger Indentation Layout 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 copper solder distribution, leading to potential cracking and reduced lifespan.
Innovation Solution
Designing a plate heat exchanger with alternating types of indentations on each plate, varying in number, size, shape, and arrangement to optimize fluid flow and mechanical stability, allowing for different fluid channel designs that adapt to fluid pressures and characteristics, thereby reducing material thickness and enhancing heat transfer efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If relatively thick metal sheets are used to withstand high pressures, then the heat exchanger can handle high pressure, but the material flow becomes unfavorable and cracks can appear in the plates
Solution Approach 1:
The patent changes the geometric parameters of the plate design by introducing a specific pattern of recesses and protrusions that redirect stress flow. This modifies how pressure is distributed through the plate structure, allowing thinner materials to withstand high pressures without developing unfavorable stress concentrations that lead to cracking.
Solution Approach 2:
The patent employs a composite structure combining metal plates with integrated recess-protrusion features. This composite design creates a more efficient stress distribution system compared to uniform thick plates, improving reliability while reducing material usage and cracking risk.
2Shape
If the press tool pressure is increased to form thick plates into the herringbone pattern, then the plates can be formed, but the manufacturing complexity and risk of defects increase
Solution Approach 1:
The patent modifies the geometric parameters of the plate design to create a pattern that is more amenable to forming processes. The specific configuration of recesses and protrusions allows the herringbone pattern to be formed with lower press tool pressures, reducing manufacturing complexity and defect risk while maintaining the desired shape.
3Strength
If copper or copper alloy solder is used to braze the joints, then the joints are formed, but the solder material collects at the crossing points of the indentations resulting in small surface area and strength
Solution Approach 1:
The patent changes the geometric parameters of the plate design to create an optimized solder distribution pattern. The specific configuration of recesses and protrusions guides solder flow and distribution during the brazing process, ensuring adequate solder coverage and joint strength while preventing excessive accumulation at indentation crossing points.
4Volume of moving object
If the herringbone pattern is used, then the heat exchanger can be compact, but the flow rate varies greatly leading to high pressure drop and reduced heat transfer efficiency
Solution Approach 1:
The patent modifies the geometric parameters of the flow channel pattern while maintaining the compact herringbone configuration. The optimized arrangement of recesses and protrusions creates more uniform flow distribution, reducing turbulence and pressure drop while preserving the compact design. This results in lower energy losses during fluid transport.
5Shape
If the herringbone pattern is used, then the heat exchanger structure is formed, but the ridges and valleys cause large variation in flow rate reducing heat transfer rate
Solution Approach 1:
The patent optimizes the geometric parameters of the herringbone structure by adjusting the dimensions and arrangement of recesses and protrusions. This modification reduces the severity of flow rate variations caused by ridges and valleys, leading to more uniform heat transfer across the plate surface while maintaining the compact herringbone configuration.
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 proposed design improves mechanical stability, reduces pressure drop, and increases heat transfer efficiency by optimizing fluid flow patterns and channel configurations, leading to a more effective and durable heat exchanger with reduced material usage and energy consumption.
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
the relatively thick plates also require a high pressure in the press tool
Implementation Method 3
the joints are typically brazed with copper or a copper alloy solder placed between the plates
Data Source
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.