Shower Heat Exchanger Structure With Frustoconical Plates
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Solution Overview
Problem
Current heat exchangers for bathing showers have complex structural designs, leading to high manufacturing costs and prices, which discourages consumer adoption and limits environmental benefits due to increased carbon footprint.
Innovation Solution
A simplified manufacturing process using non-magnetic corrosion-resistant metal plates with frustoconical indentations and spot welding, combined with an adiabatic layer, to create a cost-effective and efficient heat exchanger that enhances energy saving by recycling hot shower water.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a complex structural design is used for heat exchangers, then heat exchange efficiency can be improved, but manufacturing costs and device complexity increase significantly
Solution Approach 1:
The heat exchanger is divided into an upper heat exchange component and a lower heat exchange component, each with specific frustoconical indentation patterns. This segmentation allows for optimized heat exchange surfaces while maintaining manufacturing simplicity through standardized fabrication processes for each component.
Solution Approach 2:
Frustoconical indentations are introduced to transform the flat heat exchange surfaces into three-dimensional structured surfaces. This dimensional change increases the effective heat exchange area without proportionally increasing manufacturing complexity, as the indentations can be formed through standard stamping or molding processes.
2Reliability
If complex manufacturing processes are used, then product performance can be improved, but manufacturing time and costs increase
Solution Approach 1:
The upper and lower heat exchange components are joined through welding to form an integrated assembly. This merging approach ensures reliable thermal contact and structural integrity while simplifying the manufacturing process compared to multi-component assemblies with multiple connection points.
Solution Approach 2:
The frustoconical indentations modify the physical parameters of the heat exchange surfaces, creating optimized thermal pathways. These geometric parameter changes enhance heat transfer efficiency and durability without requiring complex manufacturing processes, as the shapes can be achieved through conventional forming methods.
3Ease of manufacture
If simplified structural design is implemented, then manufacturing costs decrease, but heat exchange efficiency may be compromised
Solution Approach 1:
Frustoconical (curved) indentations are used instead of flat surfaces to maximize heat exchange area within a compact volume. The curved geometry optimizes thermal contact and fluid flow patterns, enhancing heat transfer efficiency while the shapes can be formed through standard molding or stamping processes, maintaining manufacturing simplicity.
4Reliability
If high manufacturing costs are incurred, then product quality can be improved, but consumer affordability and adoption rate decrease
Solution Approach 1:
The heat exchanger components are designed to be manufactured from common materials using economical processes, making the product affordable for consumers. The design prioritizes cost-effective fabrication while maintaining sufficient durability for the intended application lifecycle, enabling widespread adoption for energy saving purposes.
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 reduces manufacturing costs and prices, increases energy saving efficiency, and promotes consumer adoption, while reducing carbon emissions and extending the product's service life.
Implementation Method 1
an adiabatic layer, to create a cost-effective and efficient heat exchanger
Implementation Method 2
incoming cold tap water running through the heat exchanger is heated up by hot waste water from the shower
Implementation Method 3
The design concept is that incoming cold tap water running through the heat exchanger is heated up by hot waste water from the shower
Data Source
AI summary
A manufacturing method and structure of a heat exchanger for a bathing shower involves two plates welded together to form a passage for cold water. Hot water from the shower drips onto the upper plate and transfer heat to cold water flowing through the passage between the plates. The upper plate may be spot welded to the lower plate at bottoms of frustoconical indentations in the lower plate, the plates may sandwich an adiabatic layer, and/or the passage between the plates may be formed by pipes situated between the plates.