Stacked Forming Rollers for Flexible Heat Exchanger Profiles
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Solution Overview
Problem
The conventional method of forming heat transfer elements in heat exchangers using machined rollers is cumbersome, time-consuming, and economically inefficient, limiting the geometry of the heat transfer characteristics and requiring frequent loading and unloading of rollers for different profiles.
Innovation Solution
A method using a pair of rollers with stacked, laser-cut or water-jet cut roller elements on a central shaft, allowing for easy formation of heat transfer elements with varied geometrical characteristics such as undulations, corrugations, and notches, without the need for extensive machining and reducing the time and cost associated with conventional methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional machining methods are used to create geometrical characteristics on rollers, then the heat transfer elements can be formed with precise characteristics, but the process becomes very time-consuming, cumbersome and uneconomical
Solution Approach 1:
The patent replaces conventional mechanical machining methods with a molding process where plate-like blades are arranged on a central shaft to form the roller. This substitution eliminates the time-consuming machining operations while maintaining the ability to create precise geometrical characteristics through the molding approach.
Solution Approach 2:
The roller is segmented into multiple plate-like blades that are arranged on a central shaft. Each blade can be independently formed with specific geometrical characteristics, and these segmented blades collectively create the complete roller profile. This segmentation allows for easier manufacturing and assembly compared to forming the entire roller as a single machined piece.
2Manufacturing precision
If conventional machining methods are used to create roller characteristics, then the heat transfer elements can be formed, but the process limits the characteristics to current machining technologies and practices
Solution Approach 1:
The patent enables parameter changes by allowing the plate-like blades to be formed with various geometrical characteristics that are not limited by conventional machining constraints. The molding process can create complex shapes, undulations, corrugations, and other geometries more easily than traditional machining, thus expanding the range of possible heat transfer element characteristics.
3Adaptability or versatility
If metallic rollers with varying characteristics are used for different heat transfer element profiles, then different geometries can be formed, but frequent loading and unloading of rollers adds to the overall tediousness and time
Solution Approach 1:
The patent introduces dynamics by making the roller configuration changeable through the arrangement of plate-like blades on a central shaft. Different blade arrangements can be configured to create various roller characteristics, allowing the system to adapt to different heat transfer element profiles without requiring physical replacement of entire rollers. This dynamic reconfiguration capability eliminates the need for frequent loading and unloading operations.
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
This approach significantly reduces the time and cost of forming heat transfer elements, allows for more flexible and varied geometries, and eliminates the need for frequent roller loading and unloading, making the process more economical and efficient.
Implementation Method 1
each roller element (120) is a thin metallic sheet, cut by one of a laser cutting process or a water-jet cutting process
Implementation Method 2
each roller element (120) is a thin metallic sheet, cut by one of a laser cutting process or a water-jet cutting process
Implementation Method 3
feeding a metallic sheet through the nip between the rollers (100) to form a heat transfer element
Data Source
Figure 1A~1B
Figure 1C
Figure 2A~2B
AI summary
A roller 100 for forming heat transfer elements 400 may include a central shaft 110 and a plurality of roller elements 120. The plurality of roller elements 120 may be stacked on the central shaft 110. Each roller element 120 defines an outer periphery 122, which is configured to include a geometrical characteristic 130 thereacross. The stacked roller elements 120, either stacked on the central shaft 110 or stacked without using the central shaft 110, configures the roller 100 with a circumferential surface 150 corresponding to the geometrical characteristic 130 of the stacked roller elements 120, to form the heat transfer elements 400 corresponding to the circumferential surface 150.