Shell-and-Tube Baffle Sealing to Reduce Bypass Flow

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Solution Overview

Problem

Shell-and-tube heat exchangers suffer from reduced heat transfer performance due to bypass flows through gaps between deflector plates and the housing wall, which are caused by production-related out-of-roundness and tolerances, and conventional sealing materials are not compatible with a wide range of media and temperature/pressure conditions.

Innovation Solution

A shell-and-tube heat exchanger with a sealing element that seals the gap between deflector plates and the housing wall, using elastic tabs made from thin sheet metal to compensate for manufacturing tolerances and improve flow deflection, featuring angled tabs and a V-shaped slot design to minimize gaps and enhance sealing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional sealing materials such as EPDM or silicone are used to seal the gap between deflector plates and housing wall, then assembly is enabled, but compatibility with a wide range of media and temperature/pressure ranges is limited

Engineering Contradiction:

Improveassembly capabilityVSAvoidcompatibility with media and temperature/pressure ranges

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The sealing element is made from metal material and formed into an elastic strip with specific cross-sectional geometry (rounded corner design) to change the physical parameters of the sealing material, enabling it to withstand wide temperature and pressure ranges while maintaining elasticity for effective sealing across various media conditions

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The sealing element combines metal material properties (temperature/pressure resistance) with elastic deformation capability through specific geometric design (rounded corners and strip configuration), creating a composite solution that achieves both mechanical strength and sealing flexibility

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If gaps between deflector plates and housing wall are left open to enable assembly, then assembly is facilitated, but bypass flows occur that reduce flow velocity and heat transfer performance

Engineering Contradiction:

Improveassembly facilitationVSAvoidheat transfer performance

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The sealing element is designed as an elastic strip with rounded corners that can deform to conform to the gap between the deflector plate and housing wall, creating an effective seal that prevents bypass flows while maintaining assembly capability through the flexible sealing mechanism

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The sealing element uses a simple metal strip design with rounded corners that can be easily manufactured and replaced if needed, providing a cost-effective solution that addresses the bypass flow problem without complex mechanisms

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 significantly enhances heat transfer efficiency by reducing bypass flows and maintaining effective sealing across various media and temperature/pressure conditions, facilitating easy assembly and maintenance.

Implementation Method 1

at least one sealing element (40) made from a metal material and formed into an elastic strip with a cross-section whose corners are rounded

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

heat can be transferred in the interior space between the two media

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Implementation Method 3

Deflector plates are typically arranged in the interior space of the housing, through which the first medium in the interior space is deflected along a flow path

Methodology Applied

Scientific EffectFlow deflection:

Data Source

PatentUS20260043624A1Shell-and-tube heat exchanger and cooling or heating system comprising a shell-and-tube heat exchanger

Publication Date: 2026.02.12 BITZER KUEHLMASCHINENBAU GMBH

AI summary

The present invention relates to a shell-and-tube heat exchanger (2), comprising a housing (10) which extends along a longitudinal axis (X) and comprising a housing wall (16) enclosing an interior space (15), a tube bundle (20) with a plurality of tubes (25) which are guided through the interior space (15) along the longitudinal axis (X), and at least one deflector plate (30), wherein at least one sealing element (40) is arranged which seals a gap (19) between the at least one deflector plate (30) and the housing wall (16), wherein the at least one sealing element (40) comprises a first portion (41) and a second portion (42) angled towards the first portion (41), and wherein the second portion (42) comprises at least two tabs (45) which project from the first portion (41). In addition, the present invention relates to a cooling or heating system (1).