Tube Bundle Geometry Optimization for Heat Exchanger Weight Reduction

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Solution Overview

Problem

Existing heat exchangers with tube bundles face limitations in efficiency and weight reduction due to constraints in winglet configuration and material thinning, which affect heat exchange and flow cross-section optimization.

Innovation Solution

The heat exchanger design involves arranging tube bodies within the outer casing to maximize the total outer surface area by adjusting their dimensions and spacing, ensuring a ratio of outer circumferences to inner circumference of at least 5.5 and filling the inner surface to a maximum of 64%, allowing for improved heat exchange and reduced weight.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If winglets are added to tube bodies to improve heat exchange efficiency, then heat exchange efficiency is improved, but device complexity and manufacturing difficulty increase

Engineering Contradiction:

Improveheat exchange efficiencyVSAvoiddevice complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent removes the winglet elements from the tube body design, extracting the complexity-inducing feature while maintaining the core heat exchange function through optimized tube arrangement and geometry. This resolves the contradiction by eliminating the source of manufacturing complexity while preserving productivity through alternative design means.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of adding protruding winglet elements to enhance heat exchange, the patent inverts the approach by optimizing the fundamental tube geometry and arrangement. The focus shifts from adding complex attachments to refining the basic structural configuration, thereby improving heat exchange efficiency without increasing device complexity.

Inventive Principle:

Principle #13The other way round (Inversion)

2Productivity

If tube body dimensions are reduced to increase outer surface area, then heat exchange efficiency and weight reduction are improved, but flow cross-section for the first fluid is reduced

Engineering Contradiction:

Improveheat exchange efficiencyVSAvoidflow cross-section

Core Design Contradiction:

ProductivityVSVolume of moving object

Solution Approach 1:

The patent addresses the contradiction by transitioning from reducing tube body dimensions in all directions to optimizing the arrangement and relative positioning of multiple tube bodies. By utilizing the spatial dimensionality and optimizing the configuration of the tube bundle as a whole, the design achieves increased effective heat exchange surface area while preserving adequate flow cross-sections for the first fluid.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The patent applies parameter changes by optimizing geometric parameters such as tube spacing, bundle arrangement, and relative positioning rather than simply reducing individual tube dimensions. This allows the system to achieve higher effective heat exchange surface area while maintaining sufficient flow cross-sections through carefully adjusted dimensional parameters.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If tube bodies are directly moulded onto the associated tube body to create winglets, then heat exchange efficiency is improved, but material thinning and wall thickness reduction occur

Engineering Contradiction:

Improveheat exchange efficiencyVSAvoidwall thickness

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The patent extracts and removes the winglet feature that causes material thinning and wall thickness reduction. By eliminating this design element, the patent prevents the associated manufacturing issues while maintaining heat exchange efficiency through alternative optimization approaches focused on tube arrangement and geometry.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent adopts a simpler, more robust tube body design without fragile or thin-walled protruding elements. By using straightforward tube geometries that can be manufactured with consistent wall thickness, the design prioritizes manufacturing reliability and structural integrity over complex heat exchange enhancements that compromise wall strength.

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

This design enhances heat exchange efficiency and reduces the weight of the heat exchanger while maintaining adequate flow cross-sections for the first fluid, making it suitable for applications like exhaust gas cooling.

Implementation Method 1

a heat exchange between the fluids occurs

Methodology Applied

Scientific EffectHeat exchange: Conduction (thermal)

Data Source

PatentUS11236952B2Heat exchanger

Publication Date: 2022.02.01 MAHLE INT GMBH

AI summary

A heat exchanger may include an outer casing extending in a longitudinal direction and delimiting a volume through which a first fluid is flowable, and a tube bundle including a plurality of tube bodies arranged in the volume and through which a second fluid is flowable. In a cross section, the volume may have an inner surface area and an inner circumference and each tube body may have an outer circumference and an outer surface area. A ratio of a sum of the outer circumferences to the inner circumference may be at least 5.5, and a sum of the outer surface areas may account for 64% or less of the inner surface area. A residual cross section area of the inner surface area may be delimited between the outer casing and the plurality of tube bodies.