Push-Fit Heat Exchanger Duct Assembly With Single-Motor Airflow
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Solution Overview
Problem
Existing heat exchangers for buildings are inefficient in terms of energy usage, complex and costly to assemble and install, as they often require permanent fixings and multiple components.
Innovation Solution
A heat exchanger design featuring ducts mounted on resiliently deformable end plates without permanent fixings, with a single motor driving axial and radial impellers for efficient air flow and heat exchange, allowing for quick and simple assembly and installation by pressing components together and using a push-fit mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If permanent fixings such as welding, adhesive, nuts and bolts are used to mount ducts on heat exchangers, then the structural strength and reliability are improved, but the assembly complexity and manufacturing cost increase
Solution Approach 1:
The end plates are made from resiliently deformable material that deforms around the duct to engage and retain it. This flexible material approach eliminates the need for permanent fixings while maintaining reliable connection through elastic deformation and friction engagement.
Solution Approach 2:
The patent replaces traditional mechanical fastening systems (welding, adhesive, nuts and bolts) with a deformation-based engagement system where the resilient end plates conform to and grip the ducts, simplifying the assembly process while maintaining structural integrity.
2Adaptability or versatility
If multiple separate components are used in heat exchanger assembly, then the adaptability and ease of installation are improved, but the assembly time and manufacturing cost increase
Solution Approach 1:
The patent combines the end plate and duct retention function into a single integrated component. The end plate simultaneously serves as a structural element and a retention mechanism that deforms around the duct, eliminating the need for separate fasteners and reducing assembly steps.
Solution Approach 2:
The resiliently deformable end plate automatically engages and secures the duct through its own elastic deformation when the duct is inserted, without requiring additional fastening operations or separate retention components.
3Loss of energy
If traditional heat exchanger designs are used, then the heat transfer function is maintained, but the energy efficiency is reduced due to higher operating speeds and greater complexity
Solution Approach 1:
The patent changes the operational parameters by using a single motor to drive both impellers, reducing the system's energy consumption. The simplified design with fewer components and lower operating speeds achieves the same heat transfer function with improved energy efficiency.
4Ease of manufacture
If resiliently deformable end plates are used to retain ducts without permanent fixings, then the assembly simplicity and manufacturing cost are reduced, but the potential for connection reliability issues increases
Solution Approach 1:
The end plates are made from resiliently deformable material that deforms around the duct to engage the or each duct so as to retain the or each duct on the end plates. This flexible material approach eliminates the need for permanent fixings while maintaining reliable connection through elastic deformation and friction engagement.
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 enhances energy efficiency, reduces assembly and installation complexity and costs by eliminating the need for permanent fixings and using modular components that can be easily assembled and installed without additional mountings, while maintaining airtight seals and efficient heat transfer.
Implementation Method 1
the end plates are made from a resiliently deformable material that deforms around the or each duct to engage the or each duct so as to retain the or each duct on the end plates
Implementation Method 2
heat from the two air flows being exchanged so that the incoming supply air is heated as it is forced into the building
Implementation Method 3
fans to force warm, damp exhaust air from the building and to force cold, dry, supply air into the building, heat from the two air flows being exchanged
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A heat exchanger (1) comprises impeller means (41) through which, in use, supply fluid and exhaust fluid is forced past a heat exchanger element (23). An output shaft (39) of the impeller motor (37) is operative to drive a first impeller (43) of the impeller means (41) to force the supply fluid in a first direction through the heat exchanger (1), the motor output shaft (39) being further operative to drive a second impeller (47) of the impeller means (41) to force the exhaust fluid through the heat exchanger (1) in another direction to that of the supply fluid. The heat exchanger element (23) comprises at least one duct (25) sealingly mounted on the heat exchanger (1) using only the engagement of the material of the duct (25) with the material of the heat exchanger (1).