Segmented Heat Exchanger Cap with Abutment Walls
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Solution Overview
Problem
Existing heat exchanger caps for cooling the human head are oversized and do not conform well to individual head shapes, leading to inadequate cooling due to gaps at the front, back, and top, as they deform excessively when fitted.
Innovation Solution
A heat exchanger cap design comprising separate elements for the sides and an intermediate element for the top, with abutment walls and a boustrophedonic passageway route, allowing for a closer fit to the head shape and resistance to distortion, along with a method of manufacture using interchangeable formers to accommodate different head sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single tube is wrapped around a dome shaped former to form a spherical cap, then the cap can be manufactured with a simple structure, but the cap becomes oversized and does not conform well to individual head shapes, creating gaps at the front, back, and top
Solution Approach 1:
The cap is divided into multiple separate elements (front element, rear element, and intermediate joining element) that can be assembled together. Each element is formed from separate tubes wrapped around formers, allowing the cap to be constructed from modular components that better adapt to head contours while maintaining manufacturing simplicity
Solution Approach 2:
The cap elements are designed with flexible connections and abutment walls that allow the structure to dynamically adjust and deform to match the contours of individual heads. The intermediate joining element with its abutment walls provides a mechanism for the cap to adapt its shape while maintaining structural integrity
2Manufacturing precision
If the cap is drawn in towards the patient's head to make contact and improve thermal conduction, then heat transfer efficiency is improved, but the front and rear of the cap are pushed away from their original position, creating gaps
Solution Approach 1:
By segmenting the cap into multiple elements connected by intermediate joining elements with abutment walls, the structure can locally deform at the connections while maintaining contact pressure at the cooling surfaces. The abutment walls act as hinges that allow controlled deformation without compromising overall cap position or creating gaps at the front, back, or top
Solution Approach 2:
The cap design allows different regions to have different degrees of deformation through the flexible connections and abutment walls. This enables the cap to maintain optimal contact pressure parameters at the cooling surfaces while accommodating variations in head shape, preventing the front and rear from being pushed away
3Adaptability or versatility
If multiple sizes of caps are provided to accommodate different head sizes, then adaptability to different patients is improved, but manufacturing complexity and cost increase due to needing multiple former units
Solution Approach 1:
The cap is segmented into modular elements that can be manufactured using standard formers and then assembled in different configurations. The intermediate joining element with abutment walls serves as a universal connector that can join different element combinations, allowing multiple cap sizes to be produced from the same set of standard formers without requiring custom formers for each size
Solution Approach 2:
The intermediate joining element with its abutment walls serves multiple functions: it connects different cap elements, provides structural support, allows flexible deformation, and accommodates different cap sizes. This universal component enables a single design platform to produce caps of various sizes, reducing the need for multiple specialized former units
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 cap provides a closer fit to the head, ensuring effective thermal conduction and heat transfer across a larger percentage of the head surface, simplifying manufacturing and reducing production costs by allowing for various sizes without the need for multiple former units.
Implementation Method 1
In order to seek to achieve good levels of thermal conduction, and hence heat transfer, between the patient and the cap 10
Implementation Method 2
coolant is pumped from the inlet 14 to the outlet 16 to thereby remove heat from a contact area with the patient
Data Source
AI summary
A heat exchanger cap, and method of manufacture of a heat exchanger cap configured to conform to a human head the cap comprising a first element for covering one side of the head; a second element for covering the other side of the head; and an intermediate joining element joined to, and which spaces apart, the first element and second element. Each of the elements define a single passageway for the passage of fluid through the cap. Each of the elements are provided with a flow interface in the region where the elements are joined. The flow interface defines an inlet for the passage of fluid into the passageway of one of the elements, and an outlet for the passage of fluid from the passageway out of the same element.