Segmented Fin Heat Exchanger Channels for Stable Heat Transfer
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Solution Overview
Problem
Existing heat exchangers struggle to balance efficient heat transfer, mechanical stability, material consumption, and manufacturing costs.
Innovation Solution
A heat exchanger design featuring alternating channels with fin structures formed of folded sheets, where each fin structure has parts positioned at specific intervals to prevent deformation and optimize flow, allowing for longer channels without manufacturability constraints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If continuous fin structures are used in all channels, then heat transfer efficiency is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The fin structures are segmented into first and second parts with interfaces positioned at different longitudinal locations in alternating channels. This segmentation allows the fin structures to be manufactured separately and assembled, reducing manufacturing complexity while maintaining heat transfer efficiency through the distributed interface configuration.
Solution Approach 2:
Different channel configurations are implemented locally: odd-numbered channels have interfaces at one longitudinal location while even-numbered channels have interfaces at different longitudinal locations. This local variation optimizes the overall heat transfer performance while enabling simplified manufacturing of individual fin structure components.
2Productivity
If fin structures are positioned close together, then heat transfer efficiency is improved, but mechanical stability decreases due to deformation
Solution Approach 1:
By dividing fin structures into segments with interfaces at different longitudinal positions in alternating channels, the design prevents continuous deformation propagation while maintaining adequate fin distribution for heat transfer. The segmented configuration creates mechanical breaks that stabilize the overall structure.
Solution Approach 2:
The interfaces of fin structures are deliberately positioned asymmetrically - at different longitudinal locations in alternating channels - to prevent uniform deformation patterns. This asymmetric positioning disrupts potential deformation waves and enhances mechanical stability while preserving heat transfer efficiency.
3Productivity
If channel length is increased to improve heat transfer, then productivity is improved, but manufacturability decreases
Solution Approach 1:
The fin structures are divided into first and second parts that can be manufactured separately and assembled. This segmentation enables the production of longer effective channels by joining shorter manufactured segments, overcoming limitations of single-piece manufacturing while achieving the desired channel length for improved heat transfer.
Solution Approach 2:
The fin structure parts are manufactured separately to precise dimensions and then assembled in place. This preliminary manufacturing of discrete components allows for better quality control and easier fabrication of long channels, as each segment can be produced within standard manufacturing capabilities before being joined to form the complete long-channel structure.
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 enhances heat transfer efficiency, mechanical stability, and reduces material consumption while maintaining cost-effectiveness by minimizing deformation and optimizing fluid flow.
Implementation Method 1
The components of the plate heat exchangers and especially the heat exchanger plates are typically made of metal but could be made of any other material as long as it is sufficiently strong and has sufficient heat conduction properties
Implementation Method 2
fin structures formed of sheets being folded back and forth are positioned between the heat exchanger plates such that the respective fin structure abuts the heat exchanger plates defining respective fluid channel
Data Source
AI summary
A heat exchanger includes heat exchanger plates, first and second sets of channels, and in each channel in the first and second set fin structures are positioned between the heat exchanger plates. In a first channel of the first set, a first fin structure comprises at least first and second parts. In a first channel of the second set, the first channel of the second set is a neighbouring channel to the first channel of the first set, and a second fin structure comprises at least first and second parts. An interface between the first and second parts of the first fin structure extends across the fin direction and is at a first position, an interface between the first and second parts of the second fin structure extends across the fin direction and is at a second position, and the first and second positions are separated from each other.