Undulating Parting Sheets Heat Exchanger Turbulence
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Solution Overview
Problem
Conventional heat exchanger designs, while satisfactory, lack efficiency in heat transfer due to limited fluid turbulence and primary heat transfer area, necessitating an enhancement in heat exchange performance.
Innovation Solution
The introduction of a heat exchanger layer with undulating profiles on upper and lower sheets and pins connecting them, creating a fluid flowpath with increased turbulence and a larger primary heat transfer area, along with additive manufacturing for precise construction of these features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional straight parting sheets are used, then the device complexity is low, but the heat transfer efficiency is limited due to low fluid turbulence and small primary heat transfer area
Solution Approach 1:
The patent applies curvature by forming the parting sheets with undulating profiles instead of straight flat surfaces. The first and second parting sheets each have undulating profiles with varying wavelengths and phases, creating curved surfaces that increase fluid turbulence and extend the primary heat transfer area, thereby improving heat transfer efficiency while maintaining manageable structural complexity
Solution Approach 2:
The patent changes the geometric parameters of the parting sheets by introducing undulating profiles with specific wavelengths, phases, and amplitudes. By varying these parameters (different wavelengths for first and second sheets, different phases), the fluid flow characteristics are modified to increase turbulence and heat transfer area, resolving the contradiction between simplicity and heat transfer performance
2Productivity
If pins are added to connect sheets and create turbulence, then heat transfer efficiency improves, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent merges the functions of multiple components into a single integrated structure. The pins are integrated directly into the parting sheets during additive manufacturing, eliminating the need for separate manufacturing and assembly steps. This combining of functions (structural support, flow guidance, and heat transfer enhancement) into the undulating sheet design itself improves heat transfer while simplifying the manufacturing process
Solution Approach 2:
The patent utilizes additive manufacturing technology to fabricate the complex undulating profiles and integrated pins in a single process. By changing the manufacturing method to additive processes, the device can achieve complex geometries (undulating sheets with pins) that would be difficult or expensive to manufacture using conventional subtractive or assembly-based methods, thereby improving heat transfer efficiency without proportionally increasing manufacturing difficulty
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 significantly enhances heat transfer efficiency by increasing fluid turbulence and the primary heat transfer area, leading to improved heat exchange performance compared to conventional designs.
Implementation Method 1
Defining a fluid flowpath between upper and lower sheets with different undulating profiles greatly increases the turbulence of the fluid flow in the flowpath. By increasing the turbulence of the fluid flow, the heat transfer of the heat exchanger layer is increased.
Implementation Method 2
Furthermore, undulating sheets have an increased primary heat transfer area compared to conventional/straight parting sheets.
Data Source
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AI summary
A layer (30) for a heat exchanger (10) is disclosed. The layer comprises: an inlet (32); an outlet (34); an upper sheet (36); a lower sheet (38); a fluid flowpath defined between the upper sheet and lower sheet and from the inlet to the outlet; and at least one pin (100) disposed in the flowpath and connecting the upper sheet to the lower sheet; wherein the lower sheet has a first undulating profile; and wherein the upper sheet has a second undulating profile different from the first undulating profile. Also disclosed is a heat exchanger (10) including the layer (30), and a method of making a layer for a heat exchanger.