Plate-Fin Heat Exchanger Assembly to Minimize Bypass Voids
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Solution Overview
Problem
Existing plate and fin heat exchangers face challenges in assembly complexity and thermal performance, particularly due to the formation of bypass voids that reduce efficiency.
Innovation Solution
A method for assembling a plate package by pressing fin plates with oversized transversal extensions between flat plates, minimizing the radius of rounded corner portions, and adjusting distances to reduce bypass voids, followed by permanent joining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fin plates are assembled with standard transversal extension matching the heat exchange portion, then assembly is simpler, but bypass voids form on longitudinal side ends reducing thermal performance
Solution Approach 1:
The fin plate is provided with an oversized transversal extension before assembly, which preliminarily occupies the space where bypass voids would form. This preliminary dimensional configuration ensures that when the fin plate is pressed between the flat plates, the excess material prevents void formation without requiring complex assembly procedures or additional components.
Solution Approach 2:
The transversal extension dimension of the fin plate is changed from the standard size (matching heat exchange portion) to an oversized size. This parameter change in the fin plate geometry directly eliminates the bypass voids that would otherwise form, improving thermal performance while maintaining simple assembly procedures.
2Reliability
If fin plates have oversized transversal extension, then bypass voids are minimized improving thermal performance, but the fin plate requires more material and larger dimensions
Solution Approach 1:
The excess material from the oversized transversal extension is effectively 'taken out' or removed from the final functional configuration. The oversized extension serves only to prevent void formation during assembly, and any material beyond what is needed for the heat exchange portion does not contribute to the final structure, thus minimizing material waste while achieving the void elimination goal.
3Reliability
If rounded corner portions have large radius, then manufacturing is easier, but bypass voids increase reducing thermal efficiency
Solution Approach 1:
The radius parameter of the rounded corner portions is changed from large to small dimensions. This parameter change directly reduces the size of bypass voids that form at the corners, thereby improving thermal efficiency. The small radius requirement may increase manufacturing precision needs, but this is offset by the overall simplified assembly process.
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 method enhances thermal performance by minimizing bypass voids, resulting in a more compact and efficient heat exchanger structure.
Implementation Method 1
the plates are permanently joined together by brazing, which requires treatment with heat
Data Source
AI summary
A method for assembling a plate package of a plate and fin heat exchanger comprising plural flat plates and fin plates, wherein each flat plate comprises a peripheral flank portion on opposing longitudinal sides. Each flank portion is permanently joined to an adjacent flat plate such that a longitudinally extending flow channel exists between adjacent flat plates, and wherein each flat plate comprises a heat exchange portion having a transversal extension between the peripheral flank portions. The fin plates comprise longitudinally extending fins in the heat exchange portion, which fins form in a transversal direction parallel guide channels for first and second heat exchange mediums, respectively. The fin plates and flat plates are permanently attached to each other. The method comprises providing a larger fin plate than the heat exchange portion in the transversal direction and placing it onto the flat plate of the package before permanently joining the plates.