Method for producing a heat exchanger

Abstract

Disclosed herein is a method for producing a heat exchanger comprising the steps: Providing one or more support elements (1a, 1b, 1c, 1d), the support elements (1a, 1b, 1c, 1d) comprising a plurality of insertion gaps (2); Introducing a plurality of heat exchanger plates (3) having thermoplastic end portions (4) into the insertion gaps (2) such that the plurality of heat exchanger plates (3) form a stack (5) and such that at least some of the insertion gaps (2) contain a pair of thermoplastic end portions (4) of two different heat exchanger plates (3); Heating the thermoplastic end portions (4) and thereby melting the thermoplastic end portions (4) of each pair of thermoplastic end portions (4) and fusing them together to produce the heat exchanger.

Description

[0001] Method for Producing a Heat Exchanger

[0002] Field of disclosure

[0003] The present disclosure lies in the field of heat exchangers, in particular for heat ventilation air conditioning (HVAC) units and relates particularly to a method of producing, respectively assembling, a heat exchanger and to an apparatus for performing such a method.

[0004] Background, prior art

[0005] A plurality of different heat exchangers exist in the prior art. A common type of heat exchangers are air to air (respectively gas to gas) heat exchangers, which allow exchanging thermal energy between two gas streams. This is different to air to liquid heat exchangers, wherein energy is exchanged between a gas and a liquid as it is for example the case in many heat pumps.

[0006] There are for example stack heat exchangers, which can be operated in a cross-flow mode or a parallel- / counter-flow mode or cylinder type heat exchangers. Stack heat exchangers consist typically of a plurality of heat exchanger plates, in particular enthalpy heat exchanger plates, which are typically essentially flat plates being stacked on top of each other. Since the enthalpy heat exchanger plates usually are corrugated or otherwise define channel like structures, they form air flow paths for different air streams. In cross-flow heat exchangers, two air flows cross each other, which can be achieved for example by inclining the corresponding different air flow paths to each other. The simplest version of this is a heat exchanger having rectangular heat exchanger plates which define linear channels. By alternatingly stacking them in a 90° arrangement to each other, a cross-flow heat exchanger results. Parallel- / counter-flow heat exchangers on the other hand have parallel flow paths in which two air streams can either be transported in the same direction (parallel-flow heat exchanger) of in opposite directions (counter-flow heat exchanger). Such parallel- / counter- flow heat exchangers are often made by stacking hexagonally shaped heat exchanger plates on top of each other. These heat exchanger plates may for example consist of two opposing trigonal lateral sections and a rectangular central section being arranged there between. The central section typically provides parallel flow paths and the trigonal sections serve as air entering sections which operate in a cross-flow mode. Such heat exchangers are for example disclosed in WO18020392 and WO16116806 by the applicant being included by reference in their entirety.

[0007] For manufacturing such heat exchangers, individual heat exchanger plates are stacked on top of each other. Typically left-handed and right-handed heat exchanger plates are alternatingly stacked on top of each other. Then, the adjacent heat exchanger plates have to be connected together and in a fluid tight manner. This is necessary to ensure that any air only passes through the desired airflow paths. Such connection can be done by using glues or by welding. Most commonly however, pairs of exchanger plates are sequentially connected to each other one after another, which results in a laborious and time consuming manufacturing method. Furthermore, welding typically requires the use of a welding wire, which also makes the connection of individual heat exchanger plates laborious. An additional disadvantage of known connection methods is that the connections fluctuate. It may often be the case that when every connection is done separately that certain connections are not fluid tight and / or not as reliable as others.

[0008] Summary of disclosure

[0009] It is the general object of the present disclosure to advance the state of the art in the field of production of heat exchangers and preferably to overcome the disadvantages of the prior art fully or at least partly. In advantageous embodiments, a method and apparatus are provided which allow a simple, fast and / or reliable production of a heat exchanger.

[0010] The general object is achieved by the subject-matter of the independent claims. Further advantageous embodiments follow from the dependent claims and the overall disclosure. A first aspect of the disclosure relates to a method for producing a heat exchanger, in particular an air to air heat exchanger, and a second aspect relates to an apparatus being configured for producing a heat exchanger according to any of the embodiments of the first aspect. It is clear that such an apparatus can be used in any of the embodiments of the method according to the first aspect.

[0011] A heat exchanger typically comprises a plurality of heat exchanger plates. In embodiments in which the heat exchanger may be an enthalpy heat exchanger, enthalpy heat exchanger plates are used which may in particular comprise a vapor permeable membrane. In certain embodiments, the membrane may be made from a textile material being coated on one side or on two opposing sides with a vapor permeable polymer film. The membrane may in some embodiments define a plurality of corrugations which form in the enthalpy heat exchanger, e.g. together with adjacent enthalpy heat exchanger plates, air flow paths through the enthalpy heat exchanger. The tern “adjacent” as used herein with respect to heat exchanger plates refers to the directly neighboring heat exchanger plates, such as the one above and / or the one below the enthalpy heat exchanger plate in question.

[0012] The heat exchanger may in some embodiments be an enthalpy heat exchanger and the heat exchanger plates may be enthalpy heat exchanger plates.

[0013] The produced heat exchanger may be a stack heat exchanger. The heat exchanger may typically be a plate, i.e. plate-type, heat exchanger. In such plate heat exchangers, a plurality of different heat exchanger plates are stacked on top of one another. Typically, the heat exchanger plates are flat (with the exception of the corrugations they may form).

[0014] The method for producing or assembling a heat exchanger may comprise the step of providing one or more support elements which each comprise, respectively define, a plurality of insertion gaps.

[0015] The method may further comprise the step of introducing a plurality of heat exchanger plates, respectively their thermoplastic end portions, into the insertion gaps of the one or more support elements such that the heat exchanger plates form together a stack. The heat exchanger plates may each have one or more thermoplastic end portions, which are inserted and / or arranged into the insertion gaps of the one or more support elements. The thermoplastic end portions are introduced and / or arranged such into the insertion gaps that at least some or all of insertion gaps (e.g. each insertion gap except the two opposing most distal ones) contain a pair (and typically only this pair) of thermoplastic end portions of two different heat exchanger plates. The thermoplastic end portions are typically arranged at the outer periphery of the corresponding heat exchanger plates. In some embodiments, the thermoplastic end portions may be lugs being particularly arranged at the outer periphery of the corresponding heat exchanger plates.

[0016] The method may further comprise the step of heating the thermoplastic end portions and thereby melting the thermoplastic end portions of the pair, in particular of each pair, of thermoplastic end portions and fusing them together to produce the heat exchanger. During heating, the thermoplastic end portions melt and fuse together. This step is typically performed after introducing the plurality of heat exchanger plates into the insertion gaps. It is understood that during heating, the thermoplastic end portions melt and undergo an inherent material bonding with each other. Typically, the heat exchanger plates are at their thermoplastic end portions exclusively connected by such an inherent material bonding connection. Thus, the method is typically devoid of additional adhesives. In some embodiments at least 2, in particular at least 5, more particular at least 10, more particular at least 20, pairs of thermoplastic end portions are fused together, in particular concomitantly, respectively at the same time.

[0017] The support elements can on the one hand provide a shielding of the remaining parts of the heat exchanger plates (i.e. the part not being the thermoplastic end portions) and they allow to easily pre-assemble pairs of heat exchanger plates to be connected in close proximity to each other before they are being heated and fused.

[0018] The heat exchanger plates can in some embodiments have a hexagonal shape. Such a hexagonal shape may comprise, or consist of, two trigonal lateral sections and a rectangular central section being arranged between the two trigonal lateral sections. The rectangular section and optionally also the two trigonal lateral section may comprise or consist of a membrane as described herein above. The rectangular section may comprise a plurality of corrugations. In certain embodiments, the trigonal lateral sections may comprise air guide plates to guide air towards the central section of away from it. The heat exchanger plates can comprise or consist of a thermoplastic material.

[0019] It is generally understood herein that the term “comprising” is interpreted as meaning that it includes those features following this term, but that it does not exclude the presence of other features, as long as they do not render the claim unworkable. On the other hand, if the wording "consist of" is used, then no further features are present apart from the ones following said wording.

[0020] In some embodiments, the stack of heat exchanger plates consists of alternatingly arranged heat exchanger plates with inverse air flow orientations, such as a alternatingly arranged left-handed and right-handed heat exchanger plates. Inverse air flow directions can mean that for example the first and second trigonal sections have differently oriented air guide plates. For example, the air guide plates may be oriented such that air flows along trigonal sections of directly adjacent heat exchanger plates in as a cross-flow.

[0021] In some embodiments, the support elements are comb support elements which have each a plurality of comb teeth being spaced apart from each other such that they define the plurality of insertion gaps between each other. Such insertion gaps of a comb support elements may be laterally open from one side, but have a limit stop on the opposing other side. This means, the thermoplastic end portions can be slid into the insertion gaps up to the limit stop. Such comb support elements are beneficial as the can be slid over all thermoplastic end portions of the heat exchanger plates at once and ensure that they are maintained in position. This simplifies the production process significantly.

[0022] In some embodiments, the comb support elements are slid laterally onto the plurality of heat exchanger plates to introduce the plurality of heat exchanger plates into the insertion gaps. The term “laterally” means that the teeth move towards and along (particularly only along) the thermoplastic end portions during sliding the comb support elements onto the plurality of heat exchanger plates. Such a sliding movement allows to rapidly produce the heat exchanger.

[0023] In some embodiments, heating the thermoplastic end portions comprises, or consists of, contactless heating, in particular infrared (IR) heating. IR heating may be a heating with electromagnetic irradiation, in particular in a range of 750 nm to 1 mm. Thus, there is no need for a welding wire or the like and the thermoplastic end portions to be fused are fused together in a contactless manner.

[0024] Typically, the heating is performed up to a temperature which is above the melting temperature of the thermoplastic end portions and / or below the melting temperature of the support elements.

[0025] In some embodiments all pairs of thermoplastic end portions being introduced into the insertion gaps are concomitantly fused together. That is, the pairs of thermoplastic end portions are not fused together sequentially (one after another) but at the same time. This improves the efficiency of the production process.

[0026] In some embodiments, the pair of thermoplastic end portions of two different heat exchanger plates are force locked to the one or more support elements, in particular by clamping. This may be achieved by the fact that the pairs of thermoplastic end portions have the same or a larger thickness than the width of the insertion gaps. However, they may be configured such that they can be compressed by the support elements and in particular the comb teeth. Thereby a force locking connection is achieved.

[0027] In some embodiments, the heat exchanger plates each have a first trigonal lateral section being delimited by two adjacent flanks being angled to each other, each comprising thermoplastic end portions (such as the thermoplastic end portions mentioned above). Thus, the first trigonal lateral section of each heat exchanger plate may have a first flank and an adjacent second flank which optionally form together the periphery of the trigonal lateral section. The angle between the two flanks may be less than 120 °, in particular less than 90°, in particular between 45° and 75°.

[0028] In some embodiments the thermoplastic end portions of the two adjacent flanks of each heat exchanger plate are introduced into insertion gaps being offset from one another. Thus, the thermoplastic end portions of a given heat exchanger plate may be offset to each other after having been introduced into the offset insertion gaps. It may be possible that they are however not offset to each other before being introduced into the insertion gaps.

[0029] In some embodiments the thermoplastic end portions of the two adjacent flanks of each heat exchanger plate, respectively its first trigonal section and / or the second trigonal section, are introduced into insertion gaps of different support elements. In certain embodiments, the stack of the plurality of heat exchanger plates comprises a first side comprising all first flanks of all heat exchanger plates and a therefrom separate and adjacent second side comprising all second flanks of all heat exchanger plates. In some embodiments the thermoplastic end portions of all first flanks of the heat exchanger plates are introduced into insertion gaps of a first support element, in particular a first comb support element and all thermoplastic end portions of all second flanks of the heat exchanger plates are introduced into insertion gaps of a second support element, in particular a second comb support element. The first and second support element may be angled to each other.

[0030] In some embodiments, the thermoplastic end portions of the two adjacent flanks (e.g. the first and second flank) of each heat exchanger plate, respectively its first trigonal section and / or the second trigonal section, are introduced such into the insertion gaps that the two adjacent flanks of each heat exchanger plate, respectively its first trigonal section and / or the second trigonal section, do not form a pair of thermoplastic end portions with end portions of the same adjacent heat exchanger plate.

[0031] In some embodiments, the thermoplastic end portions of the two adjacent flanks (e.g. the first and second flank) of each heat exchanger plate, respectively its first trigonal section and / or the second trigonal section, are introduced such into the insertion gaps that the two adjacent flanks of each heat exchanger plate except the distal most ones form a pair of thermoplastic end portions with different adjacent heat exchanger plates, respectively their thermoplastic end portions. The term “most distal heat exchanger plate” refers to the uppermost and lowermost heat exchanger plates of the stack.

[0032] For each heat exchanger plate (except the two distal most ones) of the stack the thermoplastic end portion of the first flank forms a pair with a thermoplastic end portion of a first flank of an adjacent heat exchanger plate (e.g. the directly preceding or the subsequent heat exchanger plate) and the thermoplastic end portion of the second flank forms a pair with a thermoplastic end portion of a second flank of a different adjacent heat exchanger plate (e.g. the directly subsequent or the preceding heat exchanger plate).

[0033] In other words, the thermoplastic end portions of the adjacent flanks (e.g. the first and second flank) of a given heat exchanger plate (e.g. except the two most distal ones) form alternating pairs with thermoplastic end portions of different heat exchanger plates. The thermoplastic end portion of a first flank and the thermoplastic end portion of the second flank of a given heat exchanger plate do therefore not form a pair with thermoplastic end portions of the same adjacent heat exchanger plate but with the thermoplastic end portions of different heat exchanger plates.

[0034] In some embodiments, each heat exchanger plate of the stack being arranged between two adjacent heat exchanger plates of the stack forms in a first insertion gap with one of the two adjacent heat exchanger plates a first pair of their thermoplastic end portions and in a second insertion gap (being different from the first insertion gap) with the other one of the two adjacent heat exchanger plates a second pair of their thermoplastic end portions. In certain embodiments, the first insertion gap and the second insertion gap are comprised in different support elements and / or are offset to each other. In some embodiments the two end portions of the heat exchanger plate of the stack being arranged between two adjacent heat exchanger plates which form the two pairs of thermoplastic end portions are comprised in different flanks of the heat exchanger plate, respectively of their first or second trigonal section.

[0035] In some embodiments, each comb teeth covers an opening between adjacent heat exchanger plates. Upon removal of the comb teeth, the desired air flow paths, e.g. its opening, result.

[0036] In some embodiments, the heat exchanger plates each have a second trigonal lateral section being oppositely arranged to the first trigonal lateral section and being delimited by two adjacent flanks (e.g. a third and fourth flank) being angled to each other, each having thermoplastic end portions. As outlined above, the heat exchanger plates may also comprise a central section being arranged between the first and second trigonal lateral section, as described herein above. Thus, the second trigonal lateral section of each heat exchanger plate may have a third flank and an adjacent fourth flank which optionally form together the periphery of the second trigonal lateral section. The angle between the two flanks may be less than 120 °, in particular less than 90°, in particular between 45° and 75°.

[0037] In some embodiments the thermoplastic end portions of the two adjacent flanks of each heat exchanger plate are introduced into insertion gaps of different support elements. In certain embodiments, the stack of the plurality of heat exchanger plates comprises a third side comprising all third flanks of all heat exchanger plates and a therefrom separate and adjacent fourth side comprising all fourth flanks of all heat exchanger plates. In some embodiments the thermoplastic end portions of all third flanks of the heat exchanger plates are introduced into insertion gaps of a third support element, in particular a third comb support element and all thermoplastic end portions of all fourth flanks of the heat exchanger plates are introduced into insertion gaps of a fourth support element, in particular a fourth comb support element. The third and fourth support element may be angled to each other.

[0038] In some embodiments, the thermoplastic end portions of the two adjacent flanks (e.g. the third and fourth flank) of each heat exchanger plate, respectively its first trigonal section and / or the second trigonal section, are introduced such into the insertion gaps that the two adjacent flanks of each heat exchanger plate do not form a pair of thermoplastic end portions with the same adjacent heat exchanger plate.

[0039] In some embodiments, the thermoplastic end portions of the two adjacent flanks (e.g. the third and fourth flank) of each heat exchanger plate, respectively its first trigonal section and / or the second trigonal section, are introduced such into the insertion gaps that the two adjacent flanks of each heat exchanger plate except the distal most ones form a pair of thermoplastic end portions with different adjacent heat exchanger plates.

[0040] For each heat exchanger plate (except the two distal most ones) of the stack the thermoplastic end portion of the third flank forms a pair with a thermoplastic end portion of a third flank of an adjacent heat exchanger plate (e.g. the directly preceding or the subsequent heat exchanger plate) and the thermoplastic end portion of the fourth flank forms a pair with a thermoplastic end portion of a fourth flank of a different adjacent heat exchanger plate (e.g. the directly subsequent or the preceding heat exchanger plate).

[0041] In other words, the thermoplastic end portions of the adjacent flanks (e.g. the third and fourth flank) of a given heat exchanger plate form alternating pairs with thermoplastic end portions of different heat exchanger plates. The thermoplastic end portion of a third flank and the thermoplastic end portion of the fourth flank of a given heat exchanger plate do therefore not form a pair with thermoplastic end portions of the same adjacent heat exchanger plate but with the thermoplastic end portions of different heat exchanger plates.

[0042] In some embodiments, the heat exchanger plates are introduced such into the insertion gaps that the thermoplastic end portions protrude from the one or more support elements, e.g. via a protruding portion of the thermoplastic end portions. Thus, the majority of the heat exchanger plate may be arranged behind (i.e. on one side) of the one or more support elements and at least a protruding portion of the thermoplastic end portions may protrude from the one or more support elements. This is beneficial as heating may be performed such that only the protruding portions are fused together. The rest of the heat exchanger plates may be shielded by the one or more support elements. In certain embodiments, during heating and fusing each pair of thermoplastic end portions together, a bulge forms for, respectively from, the pairs of fused thermoplastic end portions, in particular above the one or more support elements. Such a bulge may be formed from the protruding portions of the thermoplastic end portions.

[0043] In some embodiments, the one or more support elements are withdrawn from the produced heat exchanger after heating and fusing each pair of thermoplastic end portions.

[0044] In some embodiments, the stack formed in step b. comprises a first side with a plurality of pairs of thermoplastic end portions being contained in insertion gaps and a therefrom different second side with a plurality of pairs of thermoplastic end portions being contained in insertion gaps. The first side and the second side may be angled to each other and / or may be planar sides being angled to each other. Heating and fusing the thermoplastic end portions together may be performed either concomitantly on the first and the second side or it may be performed sequentially on the first side and then on the second side. If performed sequentially, the stack may be formed on a movable holder structure. The holder structure and a heater may be moved towards each other, in particular with such a distance that is sufficient to provide the thermal energy required to heat and fuse the thermoplastic end portions. After the plurality of pairs of thermoplastic end portions of the first side of the stack have been heated and fused together, the stack may be rotated by rotating the holder structure such that the plurality of pairs of thermoplastic end portions of the second side are exposed to the heater, heated and fused together.

[0045] The apparatus according to the second aspect of the disclosure is configured to perform the method according to any of the embodiments described herein, in particular with respect to the first aspect of the disclosure. Furthermore, such an apparatus can be used in any of the embodiments of this method.

[0046] The apparatus may comprise one or more support elements which each comprise, respectively define a plurality of insertion gaps. It is clear that as described above, the support elements may in some embodiments be comb support elements. The apparatus may in some embodiments also comprise a heater, in particular an IR heater.

[0047] In some embodiments, the apparatus may comprise a stacking unit. Such a stacking unit can for example be configured for holding and securing heat exchanger plates. For example, the stacking unit may comprise a plurality of adjacent recesses into which a plurality of heat exchanger plates can be inserted to provide a pre-stack of the heat exchanger plates. Thereafter, the pre-stack with the plurality of heat exchanger plates can be introduced in some embodiments of the method according to the disclosure into the insertion gaps (i.e. step b.).

[0048] In some embodiments, the apparatus also comprises a holder structure. The holder structure may be movable in the 3-dimensional space. In some embodiments, the holder structure can be configured such that it can rotate stack of heat exchanger plates and the one or more support elements with respect to the heater. In some embodiments, the holder structure can be configured to hold the one or more support elements and / or the formed stack of the plurality of heat exchanger plates and optionally also the stacking unit, and move them in the 3-dimensional space. In some embodiments, the holder structure may be rotatable. Preferably, the holder structure may be configured such that it can approach the heater (i.e. decrease the distance to the heater) and rotate around a rotation axis. It is possible that the holder structure may be configured to rotate with respect to the heater. This allows to expose different sites of the stack of heat exchanger plates to the heater one after another. In some embodiments, the holder structure can be configured such that it can rotate the stack of heat exchanger plates and the one or more support elements with respect to the heater. In some embodiments, the one or more support elements of the apparatus are configured to be withdrawable from a produced heat exchanger after heating and fusing each pair of thermoplastic end portions of two different heat exchanger plates.

[0049] In some embodiments, the support elements are comb support elements having a plurality of comb teeth being spaced apart from each other thereby defining the plurality of insertion gaps, as it has for example been described herein above. In some embodiments, the apparatus comprises two comb support elements. These two comb support elements are configured to be moved towards each other such that they form a pair of adjacent comb support elements. In particular, the comb support elements may be configured to be moved towards each other such that their comb teeth gear, respectively engage, into each other when they are moved towards each other. Furthermore, they may be configured to also move away from each other. Moving the comb support elements may in general for example be performed automatically, for example by a drive unit. The two comb elements may be arranged and / or configured such that their insertion gaps are offset to each other. In some embodiments, the two comb support elements are configured such that when they are arranged adjacent to each other, respectively when their comb teeth gear into each other, they form together the flanks of a triangle. In some embodiments, they may together form an angle of less than 120°, in particular less than 90°, in particular between 45° and 75°.

[0050] In certain embodiments, the apparatus comprises four comb support elements, wherein two comb support elements are configured to be moved towards each other such that they form a first pair of adjacent comb support elements and wherein the other two comb support elements are configured to be moved towards each other such that they form a second pair of adjacent comb support elements. For each pair of comb support elements, the comb support elements may be configured to be moved towards each other such that their comb teeth gear, respective engage, into each other when they are moved towards each other. The comb elements of each pair may be arranged and / or configured such that their insertion gaps are offset to each other. In some embodiments, the comb support elements of each pair are configured such that when they are arranged adjacent to each other, respectively when their comb teeth gear into each other, they form together the flanks of a triangle. In some embodiments, they may together form an angle of less than 120 °, in particular less than 90°, in particular between 45° and 75°.

[0051] Another aspect of the present disclosure relates to a heat exchanger, in particular an air to air heat exchanger and / or an enthalpy heat exchanger, produced by any of the embodiments of the method as described herein, in particular with respect to the first aspect of the disclosure.

[0052] Brief description of the figures

[0053] The herein described invention will be more fully understood from the detailed description given herein below and the accompanying drawings which should not be considered limiting to the invention described in the appended claims. The drawings are showing:

[0054] Fig. 1 a perspective view of a stack of heat exchanger plates which are introduced into insertions gaps of support elements;

[0055] Fig. 2 a partial sectional view of the stack of Fig. 1 ;

[0056] Fig. 3 a side view of a stack heat exchanger plates which are introduced into insertions gaps of support elements and a detailed view of the indicated area;

[0057] Fig. 4 a perspective view of a stack of heat exchanger plates which are introduced into insertions gaps of support elements and a detailed view of the indicated area;

[0058] Fig. 5 of the indicated a perspective view of a stack of heat exchanger plates which are currently being introduced into insertions gaps of support elements;

[0059] Fig. 6 a schematic illustration of an apparatus according to the present disclosure or as it can be used in a method according to the present disclosure.

[0060] Exemplary embodiments

[0061] Fig. 1 shows a stack 5 of a plurality of heat exchanger plates 3 (only the distal-most an upper heat exchanger plate is referenced for clarity purposes). Each heat exchanger plate 3 comprises one or more thermoplastic end portions 4 at its periphery. The heat exchanger plates 3 further comprise a first trigonal section 7 and a second trigonal section 9 and rectangular central section 13 arranged between them. Central section 13 defines a corrugation which defines a plurality of parallel air flow paths. First trigonal section 7 comprises two flanks 8a and 8b which are arranged at the outer periphery of the trigonal section. The flanks 8a, 8b may in this or any other embodiment comprise a thermoplastic end portion 4 of the corresponding heat exchanger plate 3.

[0062] The heat exchanger plates 3 are introduced with their corresponding thermoplastic end portions 4 into insertion gaps 2 (again only one insertion gap is referenced for clarity purposes) of four separate support elements 1a, 1 b, 1c and 1d. The support elements are in this embodiment comb support elements which will be described in more detail with reference to Fig. 3 to Fig. 5 below. It can be seen that the two support elements 1a and 1b form a first pair of adjacent support elements which meet each other and a the two other support elements 1c and 1d form a second pair of adjacent support elements which meet each other. Thereby, four flanks of each heat exchanger plate are encompassed by one of the four support elements.

[0063] Fig. 2 shows a partial sectional view of the stack 5 shown in Fig. 1 through support elements 1a and 1c. It can be seen that the stack contains multiple heat exchanger plates being stacked on top of each other.

[0064] Fig. 3 shows a view of the stack shown in Fig. 5 directly onto first and second support element 1a and 1b, which are each comb support elements. The comb structure of such comb support elements can be clearly seen. Each support element comprises a plurality of comb teeth 6a, 6b, 6c, 6d which are spaced apart from each other and form thereby the insertion gaps 2 between them. Each insertion gap contains two thermoplastic end portions

[0065] 4 of always two adjacent heat exchanger plates or in other words, two thermoplastic end portions of two always adjacent heat exchanger plates are arranged inside the insertion gaps 2. It can further be seen that the comb teeth of adjacent comb support elements 1a and 1 b gear into each other and that their insertion gaps 2 are offset to each other. It can further be seen that the thermoplastic end portions 4 of the two adjacent flanks (see for example as a comparison flanks 8a and 8b in Fig. 1) of each heat exchanger plate 3 are introduced such into insertion gaps 2 that the two adjacent flanks of each heat exchanger plate except the distal most ones (such as 3a in the top left insertion gap) form a pair of thermoplastic end portions with different adjacent heat exchanger plates (see for example pair 3a-3b or pair 3b-3c). In Fig. 3, heat exchanger plate 3a forms in the insertion gap between comb teeth 6a and 6b a pair of thermoplastic end portions with the next adjacent heat exchanger plate 3b. Heat exchanger plate 3b additionally also forms in the insertion gap between comb teeth 6c and 6d a pair of thermoplastic end portions with the next adjacent heat exchanger plate 3c.

[0066] In Fig. 4 a similar detailed view as in Fig. 3 is shown. However, here it can be clearly seen that the thermoplastic end portions 4 protrude from the comb support elements. Thus when the outside is exposed to a heater, the protruding portions of the thermoplastic end portions melt and are fused together upon which a bulge may form. However, the comb support elements 1a and 1 b shield the rest, i.e. the inner part of the heat exchanger plates, form heat and prevent their damage or melting.

[0067] Fig. 5 shows that the comb support elements are movable. During step b. (i.e. during introducing the heat exchanger plates 3 having thermoplastic end portions 4 into the insertion gaps 2 such that the plurality of heat exchanger plates 3 form a stack and such that at least some of the insertion gaps 2 contain a pair of thermoplastic end portions 4 of two different heat exchanger plates) the comb support elements can be slid laterally onto the plurality of heat exchanger plates 3. As shown, the lateral direction refers with respect to support element 1a in the direction of the indicated arrow. Thus, this means that each comb support element is from the side slid onto the heat exchanger plates 3 such that the thermoplastic end portions of the heat exchanger plates are provided inside the insertion gaps and / or such that the comb support elements move along the thermoplastic end portions. Fig. 6 shows schematically an apparatus which can be used in the method described herein. The apparatus comprises for support elements 1a, 1 b, 1c and 1d which all comprise a plurality of insertion gaps. The apparatus further comprises a heater 14, such as an IR heater, which is configured to heat the thermoplastic end portions of heat exchanger plates being introduced into the insertion gaps of support elements 1a, 1b, 1c and 1d. In addition, the apparatus contains a stacking unit 15 which is configured for holding and securing the heat exchanger plates. Furthermore, the apparatus contains a holder structure 16 which can be rotated with respect to the heater 14 as indicated by the arrow. The holder structure can also be directly connected to the stacking unit.

[0068] List of designations

[0069] 1a-1d support element

[0070] 2 insertion gap

[0071] 3, 3a-3c heat exchanger plate

[0072] 4 thermoplastic end portions

[0073] 5 stack

[0074] 6a-6d comb teeth

[0075] 7 first trigonal section

[0076] 8a, 8b flanks of first trigonal section

[0077] 9 second trigonal section

[0078] 10a, 10b flanks of second trigonal section

[0079] 11 first side of stack

[0080] 12 second side of stack

[0081] 13 central section

[0082] 14 heater

[0083] 15 stacking unit

[0084] 16 holder structure

Claims

Claims1. Method for producing a heat exchanger, the method comprising the steps: a. Providing one or more support elements (1a, 1 b, 1c, 1d), the support elements (1a, 1b, 1c, 1d) comprising a plurality of insertion gaps (2); b. Introducing a plurality of heat exchanger plates (3) having thermoplastic end portions (4) into the insertion gaps (2) such that the plurality of heat exchanger plates (3) forms a stack (5) and such that at least some of the insertion gaps (2) contain a pair of thermoplastic end portions (4) of two different heat exchanger plates (3); c. Heating the thermoplastic end portions (4) and thereby melting the thermoplastic end portions (4) of each pair of thermoplastic end portions (4) and fusing them together to produce the heat exchanger.

2. The method according to claim 1 , wherein the support elements (1a, 1 b, 1c, 1d) are comb support elements having a plurality of comb teeth (6a, 6b, 6c, 6d) being spaced apart from each other thereby defining the plurality of insertion gaps (2).

3. The method according to claim 2, wherein the comb support elements are slid laterally onto the plurality of heat exchanger plates (3) to introduce the plurality of heat exchanger plates (3) into the insertion gaps (2).

4. The method according to any of the previous claims, wherein heating the thermoplastic end portions (4) is performed by contactless heating, in particular by IR heating.

5. The method according to any of the previous claims, wherein all pairs of thermoplastic end portions (4) being introduced in the insertion gaps (2) of the same support element (1a, 1b, 1c, 1d) are concomitantly fused together.

6. The method according to any of the previous claims, wherein the pair of thermoplastic end portions (4) of two different heat exchanger plates (3) are force locked to the one or more support elements (1a, 1b, 1c, 1 d), in particular by clamping.

7. The method according to any of the previous claims, wherein each heat exchanger plate (3) of the stack (5) being arranged between two adjacent heat exchanger plates(3) of the stack (5) forms in a first insertion gap (2) with one of the two adjacent heat exchanger plates (3) a first pair of their thermoplastic end portions (4) and in a second insertion gap (2) with the other one of the two adjacent heat exchanger plates (3) a second pair of their thermoplastic end portions (4).

8. The method according to any of the previous claims, wherein the heat exchanger plates (3) each have a first trigonal lateral section (7) being delimited by two adjacent flanks (8a, 8b) being angled to each other, each comprising thermoplastic end portions (4).

9. The method according to claim 8, wherein the thermoplastic end portions (4) of the two adjacent flanks (8a, 8b) of each heat exchanger plate (3) are introduced into insertion gaps (2) being offset from one another and / or into insertion gaps (2) of different support elements (1a, 1 b, 1c, 1d).

10. The method according to claim 8 or 9, wherein the thermoplastic end portions (4) of the two adjacent flanks (8a, 8b) of each heat exchanger plate (3) are introduced such into the insertion gaps (2) that the two adjacent flanks (8a, 8b) of each heat exchanger plate (3) do not form a pair of thermoplastic end portions (4) with the same adjacent heat exchanger plate (3).

11. The method according to any of claims 8 to 10, wherein the thermoplastic end portions(4) of the two adjacent flanks (8a, 8b) of each heat exchanger plate (3) are introduced such into the insertion gaps (2) that the two adjacent flanks (8a, 8b) of each heatexchanger plate (3) except the distal most ones form a pair of thermoplastic end portions (4) with different adjacent heat exchanger plates (3).

12. The method according to any of claim 8 to 11 , wherein the heat exchanger plates (3) each have a second trigonal lateral section (9) being oppositely arranged to the first trigonal lateral section (7) and being delimited by two adjacent flanks (10a, 10b) being angled to each other, each comprising thermoplastic end portions (4).

13. The method according to any of the previous claims, wherein the heat exchanger plates (3) are introduced such into the insertion gaps (2) that the thermoplastic end portions (4) protrude from the one or more support elements (1a, 1 b, 1c, 1 d).

14. The method according to claim 13, wherein during heating and fusing each pair of thermoplastic end portions (4) together, a bulge forms for the pairs of fused thermoplastic end portions (4) above the one or more support elements (1a, 1b, 1c, 1d).

15. The method according to any of the previous claims, wherein the one or more support elements (1a, 1 b, 1c, 1 d) are withdrawn from the produced heat exchanger after step c.

16. The method according to any of the previous claims, wherein the stack (5) formed in step b. comprises a first side (11) with a plurality of pairs of thermoplastic end portions (4) being contained in insertion gaps (2) and a therefrom different second side (12) with a plurality of pairs of thermoplastic end portions (4) being contained in insertion gaps (2), wherein step c. is performed either concomitantly on the first side (11) and the second side (12) or wherein step c. is performed sequentially on the first side (11) and then on the second side (12).

17. The method according to any of the previous claims, wherein the one or more support elements (1a, 1 b, 1c, 1d) shield a center of the heat exchanger plates (3) from heat applied during step c.

18. An apparatus being configured for producing a heat exchanger according to the method according to any of the previous claims, the apparatus comprising: a. one or more support elements (1a, 1 b, 1c 1d) comprising a plurality of insertion gaps (2); b. a heater (14), in particular an IR heater; c. optionally an stacking unit (15) being configured for holding and securing heat exchanger plates (3).

19. The apparatus according to claim 18, wherein the support elements (1a, 1b, 1c, 1d) are comb support elements having a plurality of comb teeth being spaced apart from each other thereby defining the plurality of insertion gaps (2).

20. The apparatus according to claim 19, wherein the apparatus comprises four comb support elements, wherein two comb support elements are configured to be moved towards each other such that they form a first pair of adjacent comb support elements and wherein the other two comb support elements are configured to be moved towards each other such that they form a second pair of adjacent comb support elements.

21. The apparatus according to claim 20, wherein the two comb support elements of each pair of adjacent comb support elements are configured such that their comb teeth gear into each other when they are moved towards each other.

22. The apparatus according to any of claims 18 to 21, further comprising a holder structure (16), wherein the holder structure (16) can be rotated with respect to the heater (14).

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