Three-state integrated aluminum plate-fin heat exchange device and machining method thereof

Abstract

The invention discloses a three-state integrated aluminum plate-fin heat exchange device and a machining method thereof.The device comprises an upper sealing cover plate, a lower sealing cover plate and a plate-fin type core, the upper sealing cover plate and the lower sealing cover plate are distributed in parallel, the plate-fin type core is arranged between the upper sealing cover plate and the lower sealing cover plate, the plate-fin type core comprises a plurality of heat exchange units, and the heat exchange units are arranged in parallel. The multiple heat exchange units are distributed in a stacked mode in the vertical direction. The three functions of condensation, capillary throttling and evaporation are deeply fused with the plate-fin structure, a highly compact heat exchange device is formed, the structure is simplified, and the leakage risk is reduced; a single aluminum plate fin structure is adopted, an internal flow channel and a capillary structure are integrally designed, continuous and seamless state conversion of condensation, throttling and evaporation of refrigerants is completed in the same structure, energy loss in the function switching process is reduced, more accurate depressurization throttling is achieved in cooperation with capillary throttling regulation and control, the adaptability of the device is improved, and the service life of the device is prolonged. And the overall performance and the operation stability of equipment are obviously improved.

Description

Technical Field

[0001] This invention relates to the field of heat exchange equipment, and in particular to a three-state integrated aluminum plate-fin heat exchanger and its processing method. Background Technology

[0002] Traditional refrigeration systems typically employ a discrete modular design. Structurally, traditional refrigeration systems require independently configured condensers (heat transfer coefficients of only 3800W / m²K~4200W / m²K), auxiliary coolers (occupying 15%~18% of the system volume), and evaporators (with 22%~28% pressure drop losses). This discrete layout of multiple components leads to high overall structural redundancy, low space utilization, and difficulty in meeting the installation requirements of compact equipment. Numerous insurmountable technical bottlenecks severely restrict their adaptability to high-end applications. Regarding system reliability, the numerous connecting pipes between discrete modules (as many as 12~16 points) and the complex interface design increase the probability of leakage to >5.7×10⁻⁶. -4 The vulnerability of interfaces becomes even more pronounced under harsh conditions such as vibration and shock, especially during thousands of hours of operation, directly threatening the stability of system operation. Control response performance also has significant shortcomings. Due to the need for coordinated control of multiple devices, the control response time of traditional systems is often >800ms, exhibiting significant lag and making it difficult to achieve accurate and rapid matching of dynamic heat loads. Furthermore, energy efficiency degradation is a serious concern. The lengthy pipeline transmission process causes energy loss, leading to a 14%–19% decrease in the system's COP (Coefficient of Performance), which reduces operational economy and contradicts the current trend of energy conservation and emission reduction technologies.

[0003] To overcome the drawbacks of traditional refrigeration systems, existing technologies employ integrated heat exchange devices for optimization. For example, Chinese invention patent application number 201410585896.4 discloses an integrated micro heat exchanger for condensation, throttling, and evaporation, used in the field of micro-refrigeration. This device can complete refrigerant condensation, throttling, and evaporation in a single unit, simultaneously cooling a second fluid and heating a third fluid. It consists of a micro heat exchanger body X formed by vacuum hot-pressing diffusion welding of multiple layers of thin metal plates, a refrigerant inlet connector A, a refrigerant outlet connector F, a second fluid inlet connector C, a second fluid outlet connector D, a third fluid inlet connector G, and a third fluid outlet connector H. The micro heat exchanger body X is formed by stacking several thin metal sheets with different flow channels etched on their surfaces in a specific order, and then heating and pressurizing them in a vacuum environment. This invention highly integrates the condenser, throttling element, and evaporator, eliminating the need for piping connections between the three components. It has a compact structure and self-insulating properties, effectively reducing the system size when used in micro-refrigeration systems.

[0004] The integrated condensation-throttling-evaporation micro heat exchanger provided by the above solution reduces system volume and is mainly suitable for micro refrigeration systems, such as micro water source heat pump systems. Specific applications include miniaturized devices such as micro hot and cold water dispensers, desktop hot and cold beverage machines, and portable hot and cold experimental devices. However, it is designed for the normal operating conditions of micro refrigeration systems and does not consider structural stability under extreme conditions. Focusing on high-end fields such as aerospace, new energy vehicles, and compact heat pumps, which have extremely high requirements for space size, reliability, response speed, and energy efficiency, this equipment is incompatible and its performance cannot meet the needs of these high-end applications. Furthermore, the micro heat exchanger provided by the above solution is formed by vacuum diffusion welding of five types of thin plates or sheets: a front cover plate, fluid heat exchange plates, refrigerant heat exchange plates, refrigerant throttling plates, and a rear cover plate. Flow channels are formed by etching, and a vacuum insulation cavity is set in the middle to solve the heat conduction problem between the condensation zone and the evaporation zone. It only achieves throttling through a single method using micro-throttling channels. Vacuum insulation cavities are set between the condensation zone and the evaporation zone, and between the evaporation zone and the outer surface, to block heat conduction and reduce cold loss. Thermal management focuses more on insulation design.

[0005] Therefore, it is necessary to develop a three-state integrated aluminum plate-fin heat exchange device and its processing method to break through the limitations of traditional architecture and provide an integrated heat exchange solution. Summary of the Invention

[0006] The technical problem to be solved by the present invention is to address the shortcomings of the prior art by adopting an integrated aluminum plate-fin structure, which deeply integrates the three major functions of condensation, capillary throttling and evaporation with the plate-fin structure to form a highly compact heat exchange device, so as to achieve a continuous and seamless state transition of refrigerant in the plate-fin structure of "condensation → throttling → evaporation", thereby solving the technical problem mentioned in the background art.

[0007] To achieve the above objectives, this application provides the following technical solution: A three-state integrated aluminum plate-fin heat exchanger includes an upper closed cover plate, a lower closed cover plate, and a plate-fin core. The upper closed cover plate and the lower closed cover plate are distributed in parallel, and the plate-fin core is disposed between the upper closed cover plate and the lower closed cover plate. The plate-fin core includes multiple heat exchange units, which are stacked vertically.

[0008] The heat exchange unit includes at least two layers of vertically parallel partitions. A sealing assembly is filled between each pair of adjacent partitions. The sealing assembly includes a throttling seal, a front edge seal, a rear edge seal, and side seals. The front edge seal and rear edge seal are respectively positioned at the front and rear edges between adjacent partitions. The throttling seal is located between the front and rear edge seals, dividing the space between adjacent partitions into two equal areas. The side seals are located at the edges of both sides of the partitions. The adjacent partitions and the sealing assembly between them together form independent first and second refrigerant channels or first and second fluid channels. The first and second fluid channels between the partitions are distributed on both sides of the corresponding throttling seals. The fluid channels formed by the first and second fluid channels and the refrigerant channels formed by the first and second refrigerant channels are alternately superimposed vertically.

[0009] Multiple sets of fins are tightly embedded in the first refrigerant channel, the second refrigerant channel, the first fluid channel, and the second fluid channel.

[0010] Preferably, the throttling seal passes through the midpoint of the partition and is inclined. The side seals located between two adjacent partitions are symmetrically distributed about the center point of the throttling seal. The adjacent side seals in the vertical direction are staggered and have overlapping areas, so that the first refrigerant channel, the second refrigerant channel, the first fluid channel and the second fluid channel have reserved input ports and output ports at both ends respectively.

[0011] Preferably, the input port and output port of the first fluid channel are located on both sides of the end near the leading edge seal, the input port and output port of the second fluid channel are located on both sides of the end near the trailing edge seal, the input port and output port of the first refrigerant channel are located on both sides of the end near the throttling seal, the input port and output port of the second refrigerant channel are located on both sides of the end near the throttling seal, the inner diameter of the input port of the first fluid channel is smaller than the inner diameter of the corresponding output port, the inner diameter of the input port of the second fluid channel is larger than the inner diameter of the corresponding output port, the inner diameter of the input port of the first refrigerant channel is larger than the inner diameter of the corresponding output port, and the inner diameter of the input port of the second refrigerant channel is smaller than the inner diameter of the corresponding output port.

[0012] Preferably, the throttling seal has a throttling hole inside, and the throttling hole penetrates the sidewalls at both ends of the throttling seal.

[0013] Preferably, the heat exchange device further includes a first cold flow box, a hot flow box, a high-temperature and high-pressure gaseous refrigerant box, a medium-temperature and medium-pressure liquid refrigerant box, a transfer box, a low-temperature and low-pressure aerosol refrigerant box, a normal-temperature and normal-pressure gaseous refrigerant box, a second cold flow box, and a freeze flow box. The first cold flow box, the medium-temperature and medium-pressure liquid refrigerant box, the normal-temperature and normal-pressure gaseous refrigerant box, and the second cold flow box are arranged sequentially from front to back at one end of the plate-fin core. The hot flow box, the high-temperature and high-pressure gaseous refrigerant box, the transfer box, the low-temperature and low-pressure aerosol refrigerant box, and the freeze flow box are arranged sequentially from front to back at the other end of the plate-fin core. The side of the first cold flow box, the hot flow box, the high-temperature and high-pressure gaseous refrigerant box, the medium-temperature and medium-pressure liquid refrigerant box, the transfer box, the low-temperature and low-pressure aerosol refrigerant box, the normal-temperature and normal-pressure gaseous refrigerant box, the second cold flow box, and the freeze flow box facing the plate-fin core are set as open, and together with the upper and lower closing cover plates, they form a closed structure.

[0014] Preferably, the first cold flow box and the hot flow box are respectively connected to the input port and the output port of the first fluid channel; the second cold flow box and the frozen flow box are respectively connected to the input port and the output port of the second fluid channel; the high-temperature and high-pressure gaseous refrigerant box and the medium-temperature and medium-pressure liquid refrigerant box are respectively connected to the input port and the output port of the first refrigerant channel; the low-temperature and low-pressure atomized refrigerant box and the normal-temperature and normal-pressure gaseous refrigerant box are respectively connected to the input port and the output port of the second refrigerant channel; the medium-temperature and medium-pressure liquid refrigerant box is connected to the transfer box through a throttling seal and a throttling orifice opened inside it.

[0015] Preferably, the partition is made of aluminum alloy sheet, and the throttling seal, front edge seal, rear edge seal, side seal and fins are all made of aluminum alloy. The multi-layer partition and fins are alternately stacked, and the partition, fins and seal assembly are brazed to form an integral structure.

[0016] Preferably, the fins are configured as serrated metal plates, and the serrated metal plates are integrally formed from multiple "bow"-shaped aluminum alloy plates arranged in a linear array. The "bow"-shaped aluminum alloy plates have multiple arches arranged in a linear array, and adjacent sets of fins are staggered, so that the arches of adjacent sets of fins intersect and form an overflow channel.

[0017] Preferably, the thickness of the throttling seal, front edge seal, rear edge seal, and side seal between two adjacent partition layers is consistent and equal to the height of the fins.

[0018] The present invention also provides a method for processing a three-state integrated aluminum plate-fin heat exchanger, the processing procedure of which is as follows: Step 1: Prepare raw materials: Customize and process components that meet the size requirements according to design needs, including partitions. Each pair of adjacent partitions is filled with a sealing strip assembly. The sealing strip assembly includes an upper sealing cover, a lower sealing cover, a throttling seal, a leading edge seal, a trailing edge seal, a side seal, fins, as well as a first cold flow box, a hot flow box, a high-temperature and high-pressure gaseous refrigerant box, a medium-temperature and medium-pressure liquid refrigerant box, a transfer box, a low-temperature and low-pressure aerosol refrigerant box, a normal-temperature and normal-pressure gaseous refrigerant box, a second cold flow box, and a freeze flow box, for later use.

[0019] Step 2: Fabrication of the heat exchange unit: Throttling seals, leading edge seals, trailing edge seals, and side seals are arranged on the top of the partition. The throttling seals are brazed at an angle to the center of the partition surface. The leading edge and trailing edge seals are brazed to the front and rear of the partition surface, respectively. The side seals are brazed to the two edges of the partition surface. Each side seal consists of two long sections and two short sections, and there are two possible combinations of side seals: A set of side sealing structures consisting of a long sealing section and a short sealing section is used. When the two sets of side sealing structures are tightly attached to both sides of the throttling seal, the passage of the first fluid channel and the second fluid channel is partially blocked. The fluid input port and output port are formed at the two sides of one end near the front sealing strip and the rear sealing strip.

[0020] When the two sets of side sealing structures are tightly attached to the opposite side of the front and rear sealing strips, part of the passage of the first and second refrigerant channels is blocked, and the refrigerant input and output ports are formed at the two sides of the end near the throttling seal.

[0021] Multiple sets of fins are brazed closely together in each fluid channel and each refrigerant channel. Finally, the structural layers with fluid channels and the structural layers with refrigerant channels are stacked and brazed together vertically to form a heat exchange unit. The structural layers with fluid channels and the structural layers with refrigerant channels share a partition.

[0022] Step 3: Assemble the plate-fin core: Stack multiple heat exchange units vertically and braze them into a single structure to form a plate-fin core.

[0023] Step 4: Quality Inspection and Repair: Observe whether the input ports and output ports on both sides of the plate-fin core correspond. If there is a misalignment of the input ports or output ports, rework and adjust them. If the aluminum alloy sheet at the position of the input port or output port is deformed, repair it. If there is a fluid channel or a gap in the fluid channel other than the input port and output port, braze it to fill it.

[0024] After confirmation, proceed to the next step.

[0025] Step 5: Strengthen the protection of the plate-fin core: Fasten the upper and lower sealing covers at the top and bottom of the plate-fin core, respectively, and make the upper and lower sealing covers with light-shielding and heat-insulating materials.

[0026] Step Six: Connecting the Cold Flow and Refrigerant Transport Mechanisms: At the input and output ports of the fluid channels and refrigerant channels on both sides of the plate-fin core, assemble the first cold flow box, the hot flow box, the high-temperature and high-pressure gaseous refrigerant box, the medium-temperature and medium-pressure liquid refrigerant box, the transfer box, the low-temperature and low-pressure aerosol refrigerant box, the normal-temperature and normal-pressure gaseous refrigerant box, the second cold flow box, and the freezing flow box, forming a sealed structure that connects the fluid channels and the refrigerant channels, thus obtaining a three-state integrated aluminum plate-fin heat exchanger.

[0027] The present invention has the following beneficial effects: By adopting an integrated aluminum plate-fin structure design, the three major functions of condensation, capillary flow, and evaporation are deeply integrated with the plate-fin structure to form a highly compact heat exchange device, simplifying the structure and reducing the risk of leakage. The single aluminum plate-fin structure, through the integrated design of internal flow channels and capillary structure, enables the refrigerant to complete the continuous and seamless state transition of "condensation → throttling → evaporation" within the same structure, reducing energy loss during function switching. Combined with capillary flow control, it achieves more precise pressure reduction and throttling, improves the adaptability of the device, and significantly enhances the overall performance and operational stability of the equipment. It can be adapted to high-end fields such as aerospace and new energy vehicles, which have extremely high requirements for space, reliability, and energy efficiency.

[0028] By integrating functions and compacting the structure, it fundamentally solves the problems of large size, low efficiency, high cost and insufficient reliability caused by the "dispersed components and complex connections" of traditional refrigeration systems. It is especially suitable for refrigeration scenarios with strict requirements for miniaturization and high efficiency. Relying on the large specific surface area and strong heat transfer capacity of the plate and fin structure, it achieves efficient thermal management throughout the process, reduces energy loss during function switching, and takes advantage of the lightweight and good thermal conductivity of aluminum, which is more in line with the requirements of aerospace, new energy vehicles and other fields for weight and thermal conductivity efficiency. Attached Figure Description

[0029] Figure 1 This is a schematic diagram illustrating the working process of the three-state integrated aluminum plate-fin heat exchanger provided by the present invention for conveying fluid and refrigerant.

[0030] Figure 2 This is a first-view perspective view of the three-state integrated aluminum plate-fin heat exchanger provided by the present invention.

[0031] Figure 3 This is a second-view perspective perspective view of the three-state integrated aluminum plate-fin heat exchanger provided by the present invention.

[0032] Figure 4This is a top view of the three-state integrated aluminum plate-fin heat exchanger provided by the present invention.

[0033] Figure 5 For the present invention Figure 4 Three-dimensional view of the structure cut along the AA direction.

[0034] Figure 6 This is a schematic diagram of the distribution structure of the fins in the fluid channel or refrigerant channel in this invention.

[0035] Figure 7 For the present invention Figure 6 Enlarged view of a local structure.

[0036] In the diagram: Upper closed cover plate-1; Lower closed cover plate-2; Plate-fin core-3; First cold flow box-4; Hot flow box-5; High temperature and high pressure gaseous refrigerant box-6; Medium temperature and medium pressure liquid refrigerant box-7; Transfer box-8; Low temperature and low pressure aerosol refrigerant box-9; Normal temperature and normal pressure gaseous refrigerant box-10; Second cold flow box-11; Freeze flow box-12; Partition plate-301; Throttling seal-302; Front edge seal-303; Rear edge seal-304; Side seal-305; First refrigerant channel-306; Second refrigerant channel-307; First fluid channel-308; Second fluid channel-309; Fin-310; Overflow channel-311. Detailed Implementation

[0037] The present invention will now be described in further detail with reference to the accompanying drawings and specific preferred embodiments.

[0038] In the description of this invention, it should be understood that the terms "left side," "right side," "upper part," "lower part," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. "First," "second," etc., do not indicate the importance of the components, and therefore should not be construed as a limitation of this invention. The specific dimensions used in this embodiment are only for illustrating the technical solution and do not limit the scope of protection of this invention.

[0039] like Figures 1 to 7 As shown, a three-state integrated aluminum plate-fin heat exchanger includes an upper closed cover plate 1, a lower closed cover plate 2, and a plate-fin core 3. The upper closed cover plate 1 and the lower closed cover plate 2 are distributed in parallel, and the plate-fin core 3 is disposed between the upper closed cover plate 1 and the lower closed cover plate 2. The plate-fin core 3 includes multiple heat exchange units, which are stacked vertically.

[0040] The heat exchange unit includes at least two layers of vertically parallel partitions 301. A sealing assembly is filled between each pair of adjacent partitions 301. The sealing assembly includes a throttling seal 302, a front edge seal 303, a rear edge seal 304, and a side seal 305. The front edge seal 303 and the rear edge seal 304 are respectively positioned at the front and rear edges between the adjacent partitions 301. The throttling seal 302 is located between the front edge seal 303 and the rear edge seal 304, dividing the space between the adjacent partitions 301 into two equal areas. The side seal 305 is located at the two side edges of the partitions 301. The sealing assembly also includes a throttling seal 302 between the adjacent partitions 301 and the space between the two partitions 301. The sealing strip assembly together forms an independent first refrigerant channel 306 and second refrigerant channel 307 or a first fluid channel 308 and second fluid channel 309. The first fluid channel 308 and second fluid channel 309 located between the two partitions 301 are distributed on both sides of the corresponding throttling seal 302. The first refrigerant channel 306 and second refrigerant channel 307 located between the two partitions 301 are distributed on both sides of the corresponding throttling seal 302. The fluid channel formed by the first fluid channel 308 and the second fluid channel 309 and the refrigerant channel formed by the first refrigerant channel 306 and the second refrigerant channel 307 are alternately superimposed in the vertical direction.

[0041] Multiple sets of fins 310 are tightly embedded in the first refrigerant channel 306, the second refrigerant channel 307, the first fluid channel 308, and the second fluid channel 309. Sealing assemblies are located at both ends of the fins 310 and distributed between different fluids. The multiple components of the sealing assembly, together with the partition 301 and the fins 310, form independent flow channels, through which cold and hot fluids can pass. Heat exchange is achieved through the fins 310 and the partition 301. The overall structure is compact and has high heat transfer efficiency, facilitating efficient heat transfer and lightweight construction.

[0042] Furthermore, in the above technical solution, the throttling seal 302 passes through the midpoint of the partition 301 and is inclined. The side seals 305 located between two adjacent partitions 301 are symmetrically distributed about the center point of the throttling seal 302. The vertically adjacent side seals 305 are staggered and have overlapping areas, so that the first refrigerant channel 306, the second refrigerant channel 307, the first fluid channel 308 and the second fluid channel 309 are respectively reserved with input ports and output ports at both ends.

[0043] Furthermore, in the above technical solution, the input port and output port of the first fluid channel 308 are respectively located on both sides of one end near the leading edge seal 303; the input port and output port of the second fluid channel 309 are respectively located on both sides of one end near the trailing edge seal 304; the input port and output port of the first refrigerant channel 306 are respectively located on both sides of one end near the throttling seal 302; and the input port and output port of the second refrigerant channel 307 are respectively located on both sides of one end near the throttling seal 302. The inner diameter of the input port of the first fluid channel 308 is smaller than the inner diameter of the corresponding output port; the inner diameter of the input port of the second fluid channel 309 is larger than the inner diameter of the corresponding output port; the inner diameter of the input port of the first refrigerant channel 306 is larger than the inner diameter of the corresponding output port; and the inner diameter of the input port of the second refrigerant channel 307 is smaller than the inner diameter of the corresponding output port.

[0044] Furthermore, in the above technical solution, the throttling seal 302 is provided with a throttling hole inside, and the throttling hole penetrates the side walls at both ends of the throttling seal 302.

[0045] Furthermore, in the above technical solution, the heat exchange device also includes a first cold flow box 4, a heat flow box 5, a high-temperature and high-pressure gaseous refrigerant box 6, a medium-temperature and medium-pressure liquid refrigerant box 7, a transfer box 8, a low-temperature and low-pressure aerosol refrigerant box 9, a normal-temperature and normal-pressure gaseous refrigerant box 10, a second cold flow box 11, and a freeze flow box 12. The first cold flow box 4, the medium-temperature and medium-pressure liquid refrigerant box 7, the normal-temperature and normal-pressure gaseous refrigerant box 10, and the second cold flow box 11 are arranged sequentially from front to back at one end of the plate-fin core 3. The heat flow box 5, the high-temperature and high-pressure... The gaseous refrigerant box 6, the transfer box 8, the low-temperature and low-pressure aerosol refrigerant box 9, and the freeze flow box 12 are arranged sequentially from front to back at the other end of the plate-fin core 3. The first cold flow box 4, the hot flow box 5, the high-temperature and high-pressure gaseous refrigerant box 6, the medium-temperature and medium-pressure liquid refrigerant box 7, the transfer box 8, the low-temperature and low-pressure aerosol refrigerant box 9, the normal-temperature and normal-pressure gaseous refrigerant box 10, the second cold flow box 11, and the freeze flow box 12 are set to be open on the side facing the plate-fin core 3, and together with the upper closed cover plate 1 and the lower closed cover plate 2, they form a closed structure.

[0046] Furthermore, in the above technical solution, the first cold flow box 4 and the hot flow box 5 are respectively connected to the input port and the output port of the first fluid channel 308; the second cold flow box 11 and the frozen flow box 12 are respectively connected to the input port and the output port of the second fluid channel 309; the high temperature and high pressure gaseous refrigerant box 6 and the medium temperature and medium pressure liquid refrigerant box 7 are respectively connected to the input port and the output port of the first refrigerant channel 306; the low temperature and low pressure aerosol refrigerant box 9 and the normal temperature and normal pressure gaseous refrigerant box 10 are respectively connected to the input port and the output port of the second refrigerant channel 307; the medium temperature and medium pressure liquid refrigerant box 7 and the transfer box 8 are connected through the throttling seal 302 and the throttling orifice opened inside it.

[0047] Furthermore, in the above technical solution, the partition 301 is set as a thin aluminum alloy plate. The partition 301 plays the role of separating the flow channels and supporting the overall heat dissipation structure within the plate-fin core 3; it is located between adjacent refrigerant channels and fluid channels. The throttling seal 302, the leading edge seal 303, the trailing edge seal 304, the side seal 305, and the fins 310 are all made of aluminum alloy. The multi-layer partitions 301 and fins 310 are alternately stacked, and the partitions 301, fins 310, and seal assembly are brazed to form an integral structure. The fins 310 are configured as serrated metal plates, which are integrally formed from multiple linearly arrayed "bow"-shaped aluminum alloy plates. The fins 310 are sandwiched between two adjacent partition plates 301, thereby increasing the heat transfer area and enhancing heat transfer by disturbing the fluid. The "bow"-shaped aluminum alloy plates have multiple linearly arrayed arches, and adjacent sets of fins 310 are staggered, so that the arches of adjacent sets of fins 310 intersect and form an overflow channel 311. The throttling seals 302, leading edge seals 303, trailing edge seals 304, and side seals 305 between adjacent partition plates 301 have the same thickness and are equal to the height of the fins 310.

[0048] This device explicitly uses aluminum as its core manufacturing material, fully utilizing its lightweight properties to significantly reduce the overall weight of the device. This makes it perfectly suited for high-end fields such as aerospace and new energy vehicles, where weight is a critical factor. It solves the problem of traditional heat exchangers made of materials like stainless steel being too heavy and limiting their application scenarios. Combining aluminum's excellent thermal conductivity with an aluminum plate-fin structure where internal flow channels are all arranged with 310 fins, the design is optimized for the specific thermal conductivity of the material. The plate-like structure has a simple flow channel and a low turbulence coefficient, further improving heat transfer efficiency and enabling the device to achieve more efficient heat exchange within a limited space.

[0049] Specifically, this device integrates a micro-fin array 310 within the flow channel using a precision stamping process. The fin height is controlled within the range of 0.5mm to 1.0mm, and the spacing is uniformly less than 0.3mm, effectively increasing the specific surface area by more than 40% and enhancing the fluid turbulence effect, significantly improving the heat transfer coefficient to over 5000W / m²K. Simultaneously, the excellent corrosion resistance and ease of processing of aluminum, combined with the use of aluminum alloy materials with better corrosion resistance and surface treatments such as chemical oxidation, further optimizes long-term operational stability and fatigue resistance, reducing the risk of material degradation in high-vibration environments (such as the takeoff phase of aerospace vehicles). Compared to the CN104315757B patent, this targeted optimization not only solves the bottlenecks of weight and thermal conductivity, but also maintains efficient heat transfer under all operating conditions. For example, in extreme temperature difference conditions (-40℃ to 150℃), heat loss is reduced by more than 15%, directly improving the system COP value by 0.2~0.3, perfectly meeting the dual requirements of lightweight and high efficiency for high-end applications, making the heat exchange performance more advantageous.

[0050] Considering the processing characteristics of aluminum, a precision stamping process is adopted to make the internal flow channels and capillary structures of the aluminum plate fin structure more precise, meeting the functional requirements of capillary flow control and all-condition self-adaptation. However, the CN104315757B patent does not adapt and optimize the processing technology for specific materials.

[0051] Unlike the multi-layered plate structure of patent CN104315757B, this device adopts an integrated aluminum plate-fin structure, deeply integrating the three functions of condensation, capillary throttling, and evaporation with the plate-fin structure. This allows the refrigerant to achieve a continuous and seamless transition between condensation, throttling, and evaporation within the plate-fin structure, reducing energy loss during function switching, simplifying the structure, and lowering the risk of leakage. In contrast, the multi-layered plate structure of patent CN104315757B has numerous connection points, still posing a certain risk of leakage.

[0052] The flow channel layout of the plate-fin structure is optimized. Based on the functional requirements of each stage of condensation, throttling, and evaporation, differentiated flow channel sizes and distributions are designed to achieve efficient synergy between functional areas and improve overall heat exchange efficiency. Compared with the relatively uniform flow channel design of patent CN104315757B, the flow channel layout of this device is more targeted and synergistic.

[0053] The present invention also provides a method for processing a three-state integrated aluminum plate-fin heat exchanger, the processing procedure of which is as follows: Step 1: Prepare raw materials: According to the design requirements, customize and process the components that meet the size requirements, including partition 301. Each pair of adjacent partitions 301 is filled with a sealing strip assembly. The sealing strip assembly includes an upper sealing cover 1, a lower sealing cover 2, a throttling seal 302, a front edge seal 303, a rear edge seal 304, a side seal 305, fins 310, as well as a first cold flow box 4, a hot flow box 5, a high temperature and high pressure gaseous refrigerant box 6, a medium temperature and medium pressure liquid refrigerant box 7, a transfer box 8, a low temperature and low pressure aerosol refrigerant box 9, a normal temperature and normal pressure gaseous refrigerant box 10, a second cold flow box 11, and a freeze flow box 12, for later use.

[0054] Step 2: Fabrication of the heat exchange unit: Throttling seal 302, leading edge seal 303, trailing edge seal 304, and side seal 305 are arranged on the top of the partition 301. The throttling seal 302 is brazed at an angle to the center of the partition 301 surface. The leading edge seal 303 and trailing edge seal 304 are brazed to the front and rear of the partition 301 surface, respectively. The side seal 305 is brazed to the two side edges of the partition 301 surface. By rationally designing the external dimensions and installation positions of each component, the internal space of the equipment is utilized to the maximum extent, reducing the overall volume of the water source heat pump. The side seal 305 consists of two long sealing sections and two short sealing sections, and includes two combination methods.

[0055] A long sealing section and a short sealing section form a set of side sealing structures. When the two sets of side sealing structures are tightly attached to both sides of the throttling seal 302, part of the passage of the first fluid channel 308 and the second fluid channel 309 is blocked. The fluid input port and output port are formed at the positions on both sides of one end near the front sealing strip 303 and the rear sealing strip 304.

[0056] When the two sets of side sealing structures are tightly attached to the opposite side of the front sealing strip 303 and the rear sealing strip 304, part of the passage of the first refrigerant passage 306 and the second refrigerant passage 307 is blocked, and the refrigerant input port and output port are formed at the two sides of one end near the throttling sealing strip 302.

[0057] Multiple sets of fins 310 are brazed closely together in each fluid channel and each refrigerant channel. Finally, the structural layers with fluid channels and the structural layers with refrigerant channels are stacked and brazed together vertically to form a heat exchange unit. The structural layers with fluid channels and the structural layers with refrigerant channels share a partition 301.

[0058] Step 3: Assemble the plate-fin core 3: Stack multiple heat exchange units vertically and braze them into a single structure to form the plate-fin core 3.

[0059] Step 4: Quality Inspection and Repair: Observe whether the input ports and output ports on both sides of the plate-fin core 3 correspond. If the input ports or output ports are misaligned, rework and adjust them. If the aluminum alloy sheet at the input port and output port position is deformed, repair it. If there is a fluid channel or a gap in the fluid channel other than the input port and output port, braze it to fill it.

[0060] Confirm the above steps and proceed to the next step.

[0061] Step 5: Strengthen the protection of the plate-fin core 3: fasten the upper sealing cover 1 and the lower sealing cover 2 to the top and bottom of the plate-fin core 3 respectively, and the upper sealing cover 1 and the lower sealing cover 2 are made of light-shielding and heat-insulating materials.

[0062] Step Six: Connecting the Cold Flow and Refrigerant Transport Mechanisms: At the input and output ports of the fluid channels and refrigerant channels on both sides of the plate-fin core 3, assemble the first cold flow box 4, the hot flow box 5, the high-temperature and high-pressure gaseous refrigerant box 6, the medium-temperature and medium-pressure liquid refrigerant box 7, the transfer box 8, the low-temperature and low-pressure aerosol refrigerant box 9, the normal-temperature and normal-pressure gaseous refrigerant box 10, the second cold flow box 11, and the freeze flow box 12, forming a sealed structure that connects the fluid channels and the refrigerant channels, thus obtaining a three-state integrated aluminum plate-fin heat exchanger.

[0063] This application integrates condensation, capillary flow, and evaporation functions into a single plate-fin structure, eliminating redundant piping, shortening the refrigerant flow path in the core components, reducing pressure loss and ineffective heat exchange, while also reducing the number of connection points and improving system sealing and energy efficiency. Specifically: In traditional refrigeration systems, the condenser, throttling devices (such as capillary tubes and expansion valves), and evaporator are independent components that need to be connected by piping to form a circulation loop. This decentralized structure results in a large overall system size and a large space requirement, especially in scenarios with high miniaturization and integration needs (such as vehicle refrigeration, portable devices, and precision instrument cooling), where space constraints become a significant bottleneck. This application eliminates the connecting piping between traditional components and independent functional units, significantly reducing the overall system size and achieving a "highly compact" design goal, adapting to the application requirements of confined spaces.

[0064] In traditional refrigeration systems, the connecting pipes of independent components generate additional pressure and heat losses. Furthermore, the longer the pipe, the greater the refrigerant flow resistance, requiring more energy to overcome this resistance. Heat exchange between the pipes and the environment (non-target heat exchange) reduces condensation or evaporation efficiency. Increased connection points not only increase the risk of refrigerant leakage but may also lead to decreased system compatibility due to assembly errors. This application eliminates redundant pipes, shortens the refrigerant flow path in core components, reduces pressure losses and ineffective heat exchange, and simultaneously reduces the number of connection points, improving system sealing and energy utilization efficiency.

[0065] In traditional refrigeration systems, the heat transfer design of individual components is often limited to single-function optimization (e.g., condensers focus on heat dissipation, evaporators focus on heat absorption), while the "matching" between components (e.g., the connection between the refrigerant state after condensation and the throttling and evaporation requirements) significantly impacts overall efficiency. Furthermore, while plate-fin structures inherently possess highly efficient heat transfer characteristics (large specific surface area, strong turbulence promotion), they have traditionally been used only in single heat exchange stages (e.g., condensers or evaporators), failing to fully realize their potential. This application integrates three major functions into a plate-fin structure, enabling continuous and efficient transition of refrigerant states (temperature, pressure, phase) (e.g., high-pressure liquid after condensation directly passes through the capillary structure within the plate fins for throttling before entering adjacent evaporation areas), reducing energy losses during function switching. Simultaneously, the highly efficient heat transfer characteristics of the plate fins can cover the entire process, improving overall heat exchange efficiency.

[0066] Traditional refrigeration systems involve manufacturing components such as condensers, expansion valves, and evaporators, which are then assembled via piping. This process is complex, involves numerous parts, and results in long production cycles and high assembly costs. Furthermore, troubleshooting and replacing these dispersed components during later maintenance is more cumbersome. This application integrates multiple functions into a single structure, reducing the types and number of parts, simplifying the production and assembly process, and lowering manufacturing costs. Simultaneously, the simplified structure facilitates rapid fault location, reducing maintenance difficulty and costs.

[0067] This device, through comprehensive innovation in materials, structure, and function, is specifically designed for high-end fields such as aerospace, new energy vehicles, and compact heat pumps, which have extremely high requirements for space size, reliability, response speed, and energy efficiency. It solves the problem that traditional heat exchangers in these fields cannot meet the stringent requirements, expanding the high-end application scenarios of integrated heat exchangers. Through functional integration and structural compactness, it fundamentally solves the problems of large size, low efficiency, high cost, and insufficient reliability caused by the "dispersed components and complex connections" of traditional refrigeration systems. It is particularly suitable for refrigeration scenarios with strict requirements for miniaturization and high efficiency. Customized solutions are provided for the specific needs of different high-end application scenarios. For example, for the aerospace field, a special protective structure adapted to the extreme environment of space (such as vacuum and alternating high and low temperatures) is designed; for the new energy vehicle field, a compact structure adapted to vehicle vibration and spatial layout is designed.

[0068] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings, but the present invention is not limited to the described embodiments. For those skilled in the art, various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and spirit of the present invention, and these variations still fall within the protection scope of the present invention.

Claims

1. A three-state integrated aluminum plate-fin heat exchanger, comprising an upper closed cover plate (1), a lower closed cover plate (2), and a plate-fin core (3), wherein the upper closed cover plate (1) and the lower closed cover plate (2) are distributed in parallel, and the plate-fin core (3) is disposed between the upper closed cover plate (1) and the lower closed cover plate (2), characterized in that: The plate-fin core (3) includes multiple heat exchange units, which are stacked vertically. The heat exchange unit includes at least two layers of vertically parallel partitions (301). A sealing assembly is filled between each pair of adjacent partitions (301). The sealing assembly includes a throttling seal (302), a front edge seal (303), a rear edge seal (304), and a side seal (305). The front edge seal (303) and the rear edge seal (304) are respectively positioned at the front and rear edges between adjacent partitions (301). The throttling seal (302) is located between the front edge seal (303) and the rear edge seal (304), dividing the space between adjacent partitions (301) into two equal areas. The side seal (305) is located at the two side edges of the partitions (301). The two adjacent partitions (301) and the two partitions (301) are also mentioned. The sealing components between them together form an independent first refrigerant channel (306) and second refrigerant channel (307) or a first fluid channel (308) and second fluid channel (309). The first fluid channel (308) and second fluid channel (309) located between the two partitions (301) are distributed on both sides of the corresponding throttling seal (302). The first refrigerant channel (306) and second refrigerant channel (307) located between the two partitions (301) are distributed on both sides of the corresponding throttling seal (302). The fluid channel formed by the first fluid channel (308) and the second fluid channel (309) and the refrigerant channel formed by the first refrigerant channel (306) and the second refrigerant channel (307) are alternately superimposed in the vertical direction. Multiple sets of fins (310) are tightly embedded in the first refrigerant channel (306), the second refrigerant channel (307), the first fluid channel (308), and the second fluid channel (309).

2. The three-state integrated aluminum plate-fin heat exchanger according to claim 1, characterized in that: The throttling seal (302) passes through the midpoint of the partition (301) and is inclined. The side seals (305) located between two adjacent partitions (301) are symmetrically distributed about the center point of the throttling seal (302). The adjacent side seals (305) are staggered in the vertical direction and have overlapping areas, so that the input port and output port are reserved at both ends of the first refrigerant channel (306), the second refrigerant channel (307), the first fluid channel (308), and the second fluid channel (309).

3. The three-state integrated aluminum plate-fin heat exchanger according to claim 2, characterized in that: The input and output ports of the first fluid channel (308) are located on both sides of one end near the leading edge seal (303), the input and output ports of the second fluid channel (309) are located on both sides of one end near the trailing edge seal (304), the input and output ports of the first refrigerant channel (306) are located on both sides of one end near the throttling seal (302), and the input and output ports of the second refrigerant channel (307) are located on both sides of one end near the throttling seal (302). The inner diameter of the input port of the first fluid channel (308) is smaller than the inner diameter of the corresponding output port, the inner diameter of the input port of the second fluid channel (309) is larger than the inner diameter of the corresponding output port, the inner diameter of the input port of the first refrigerant channel (306) is larger than the inner diameter of the corresponding output port, and the inner diameter of the input port of the second refrigerant channel (307) is smaller than the inner diameter of the corresponding output port.

4. The three-state integrated aluminum plate-fin heat exchanger according to claim 3, characterized in that: The throttling seal (302) has a throttling hole inside, and the throttling hole penetrates the side walls at both ends of the throttling seal (302).

5. A three-state integrated aluminum plate-fin heat exchanger according to claim 4, characterized in that: The heat exchange device also includes a first cold flow box (4), a heat flow box (5), a high-temperature and high-pressure gaseous refrigerant box (6), a medium-temperature and medium-pressure liquid refrigerant box (7), a transfer box (8), a low-temperature and low-pressure aerosol refrigerant box (9), a normal-temperature and normal-pressure gaseous refrigerant box (10), a second cold flow box (11), and a freeze flow box (12). The first cold flow box (4), the medium-temperature and medium-pressure liquid refrigerant box (7), the normal-temperature and normal-pressure gaseous refrigerant box (10), and the second cold flow box (11) are arranged sequentially from front to back at one end of the plate-fin core (3). The heat flow box (5), the high-temperature and high-pressure gaseous refrigerant box (6), the medium-temperature and medium-pressure liquid refrigerant box (7), the normal-temperature and normal-pressure gaseous refrigerant box (7), the transfer box (8), the low-temperature and low-pressure aerosol refrigerant box (9), the normal-temperature and normal-pressure gaseous refrigerant box (10), the second cold flow box (8), the first cold flow box (4), the medium-temperature and medium-pressure liquid refrigerant box (7), the normal-temperature and normal-pressure gaseous refrigerant box (10), and the second cold flow box (11) are arranged sequentially from front to back at one end of the plate-fin core (3). The transfer box (8), the low-temperature and low-pressure aerosol refrigerant box (9) and the freeze flow box (12) are arranged sequentially from front to back at the other end of the plate-fin core (3). The first cold flow box (4), the hot flow box (5), the high-temperature and high-pressure gaseous refrigerant box (6), the medium-temperature and medium-pressure liquid refrigerant box (7), the transfer box (8), the low-temperature and low-pressure aerosol refrigerant box (9), the normal-temperature and normal-pressure gaseous refrigerant box (10), the second cold flow box (11) and the freeze flow box (12) are set to be open on the side facing the plate-fin core (3), and together with the upper closed cover plate (1) and the lower closed cover plate (2), they form a closed structure.

6. The three-state integrated aluminum plate-fin heat exchanger according to claim 5, characterized in that: The first cold flow box (4) and the hot flow box (5) are connected to the input port and the output port of the first fluid channel (308), respectively; the second cold flow box (11) and the frozen flow box (12) are connected to the input port and the output port of the second fluid channel (309), respectively; the high temperature and high pressure gaseous refrigerant box (6) and the medium temperature and medium pressure liquid refrigerant box (7) are connected to the input port and the output port of the first refrigerant channel (306), respectively; the low temperature and low pressure aerosol refrigerant box (9) and the normal temperature and normal pressure gaseous refrigerant box (10) are connected to the input port and the output port of the second refrigerant channel (307), respectively; the medium temperature and medium pressure liquid refrigerant box (7) and the transfer box (8) are connected through the throttling seal (302) and the throttling hole opened inside it.

7. The three-state integrated aluminum plate-fin heat exchanger according to claim 1, characterized in that: The partition (301) is made of aluminum alloy sheet. The throttling seal (302), front edge seal (303), rear edge seal (304), side seal (305) and fin (310) are all made of aluminum alloy. The multi-layer partition (301) and fin (310) are alternately stacked, and the partition (301), fin (310) and seal assembly are formed into an integral structure by brazing.

8. The three-state integrated aluminum plate-fin heat exchanger according to claim 1, characterized in that: The fins (310) are configured as serrated metal plates, and the serrated metal plates are integrally formed from multiple "bow"-shaped aluminum alloy plates arranged in a linear array. The "bow"-shaped aluminum alloy plates have multiple arches arranged in a linear array, and the adjacent two sets of fins (310) are staggered, so that the arches of the adjacent two sets of fins (310) are interlaced and form an overflow channel (311).

9. A three-state integrated aluminum plate-fin heat exchanger according to claim 1, characterized in that: The thickness of the throttling seal (302), front edge seal (303), rear edge seal (304) and side seal (305) between two adjacent partitions (301) is consistent and equal to the height of the fin (310).

10. A method for processing a three-state integrated aluminum plate-fin heat exchanger as described in any one of claims 1 to 9, characterized in that: The processing procedure is as follows: Step 1: Prepare raw materials: According to the design requirements, customize and process the components that meet the size requirements, including the upper closed cover (1), the lower closed cover (2), the partition (301), the throttling seal (302), the front edge seal (303), the rear edge seal (304), the side seal (305), the fins (310), as well as the first cold flow box (4), the hot flow box (5), the high temperature and high pressure gaseous refrigerant box (6), the medium temperature and medium pressure liquid refrigerant box (7), the transfer box (8), the low temperature and low pressure aerosol refrigerant box (9), the normal temperature and normal pressure gaseous refrigerant box (10), the second cold flow box (11), and the freeze flow box (12), for later use; Step 2: Fabrication of the heat exchange unit: Throttling seals (302), leading edge seals (303), trailing edge seals (304), and side seals (305) are arranged on the top of the partition (301). The throttling seals (302) are brazed at an angle to the middle of the surface of the partition (301). The leading edge seals (303) and trailing edge seals (304) are brazed to the front and rear of the surface of the partition (301), respectively. The side seals (305) are brazed to the two edges of the surface of the partition (301). The side seals (305) consist of two long sealing sections and two short sealing sections. The side seals (305) include two combination methods: Using a long sealing section and a short sealing section as a set of side sealing structures, when the two sets of side sealing structures are tightly attached to both sides of the throttling seal (302), the passage of the first fluid channel (308) and the second fluid channel (309) is partially blocked, and the fluid input port and output port are formed at the positions on both sides of one end near the front sealing strip (303) and the rear sealing strip (304); When the two sets of side sealing structures are tightly attached to the opposite side of the front sealing strip (303) and the rear sealing strip (304), part of the passage of the first refrigerant passage (306) and the second refrigerant passage (307) is blocked, and the refrigerant input port and output port are formed at the two sides of the end near the throttling sealing strip (302); Multiple sets of fins (310) are brazed tightly in each fluid channel and each refrigerant channel. Finally, the structural layer with fluid channel and the structural layer with refrigerant channel are stacked and brazed together in the vertical direction to form a heat exchange unit. The structural layer with fluid channel and the structural layer with refrigerant channel share a partition (301). Step 3: Assemble the plate-fin core (3): Stack multiple heat exchange units vertically and braze them into a single structure to form the plate-fin core (3). Step 4, Quality Inspection and Repair: Observe whether the input ports and output ports on both sides of the plate-fin core (3) correspond. If the input ports or output ports are misaligned, rework and adjust them. If the aluminum alloy sheet at the input port and output port position is deformed, repair it. If there is a fluid channel or a gap in the fluid channel other than the input port and output port, braze it to fill it. After confirmation, proceed to the next step; Step 5: Strengthen the protection of the plate-fin core (3): fasten the upper sealing cover (1) and the lower sealing cover (2) to the top and bottom of the plate-fin core (3) respectively, and the upper sealing cover (1) and the lower sealing cover (2) are made of light-shielding and heat-insulating materials; Step 6: Connect the cold flow and refrigerant delivery mechanism: At the input and output ports of the fluid channel and refrigerant channel on both sides of the plate-fin core (3), assemble the first cold flow box (4), the hot flow box (5), the high temperature and high pressure gaseous refrigerant box (6), the medium temperature and medium pressure liquid refrigerant box (7), the transfer box (8), the low temperature and low pressure aerosol refrigerant box (9), the normal temperature and normal pressure gaseous refrigerant box (10), the second cold flow box (11), and the freeze flow box (12), and form a sealed structure that connects the fluid channel and the refrigerant channel to obtain a three-state integrated aluminum plate-fin heat exchanger.

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