Wave-Channel Plate Heat Exchanger Modules for High-Pressure Compactness
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Solution Overview
Problem
Existing plate heat exchangers are not compact, require excessive metal raw materials, and are not suitable for high-pressure applications, particularly for heat exchange between hot and cold gases at high pressures.
Innovation Solution
A heat exchanger plate module comprising a pressed plate with a corrugated pattern and a flat plate, featuring integrated fluid ports and wave-shaped fluid channels that reduce material usage and enhance heat exchange efficiency, allowing for efficient operation under high-pressure conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If traditional plate heat exchanger designs are used, then heat exchange function is provided, but the exchanger is not compact and requires excessive metal raw materials
Solution Approach 1:
The heat exchanger is divided into modular plate units that can be stacked and connected. Each plate is a separate component with integrated flow channels, allowing the system to achieve the required heat exchange capacity through modular assembly rather than using large continuous metal structures, thereby reducing overall material consumption.
Solution Approach 2:
The patent utilizes three-dimensional wave-shaped flow channels within the plates to maximize heat exchange surface area within a compact volume. By creating complex internal geometries in the third dimension, the design achieves high heat transfer efficiency without increasing the external footprint or metal material usage.
2Quantity of substance
If traditional plate heat exchanger designs are used, then heat exchange function is provided, but excessive metal raw materials are required
Solution Approach 1:
The plates feature locally optimized structures with reinforced regions at critical stress points and thinner sections in non-critical areas. The wave-shaped channels and integrated flow paths are designed to distribute stress evenly, providing high-pressure reliability while minimizing overall material consumption through localized material placement only where structurally necessary.
Solution Approach 2:
The patent employs composite construction techniques combining different metal materials with varying properties - using stronger materials only where high-pressure resistance is critical and lighter materials where heat exchange efficiency is prioritized. This composite approach achieves reliable high-pressure performance with reduced total metal material usage.
3Productivity
If integrated fluid ports and wave-shaped channels are implemented, then heat exchange efficiency is enhanced and material usage is reduced, but manufacturing complexity increases
Solution Approach 1:
The complex wave-shaped flow channels and integrated fluid ports are pre-formed during the plate manufacturing process using molding or stamping techniques. By creating these complex geometries in advance during plate production rather than assembling them separately, the design achieves high heat exchange efficiency while keeping the overall manufacturing process manageable through standardization.
Solution Approach 2:
Multiple functions are merged into single components - the plates simultaneously serve as structural elements, heat transfer surfaces, and flow channel conduits. The fluid ports are integrated directly into the plate structure rather than being separate components. This merging reduces the total number of parts and assembly steps, offsetting the complexity of the wave-shaped channel geometry.
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 provides a robust, compact heat exchanger with reduced metal usage, capable of efficient heat exchange in high-pressure environments, while minimizing material costs and maximizing heat exchange area.
Implementation Method 1
The metal plates are used to separate two fluids and transfer heat between the fluids
Data Source
AI summary
A heat exchanger plate module comprises a pressed heat exchanger plate and a flat plate, and a heat exchanger comprises plural of the modules. The plates comprise first and second longitudinal end portions each having a fluid port, and an intermediate heat exchange portion between the first and second longitudinal end portions. The plates further include a pressed corrugated pattern with alternating tops and bottoms in the thickness direction. The pressed pattern comprises in the first and/or second longitudinal end portions, a first fluid channel pattern leading fluid flow into the fluid port and/or a second fluid channel pattern bypassing the fluid port. In the intermediate heat exchange portion, a third fluid channel pattern fluidly communicates with the first and/or second fluid channel pattern and comprises longitudinally extending wave-shaped pressed lines that form discrete longitudinal extending fluid channels, when the pressed heat exchanger plate is attached to the flat plate.