Composite Metal Heating Plate with Offset Cooling Channel
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Solution Overview
Problem
Existing methods for producing composite metal objects with embedded heating elements and cooling channels are complex and limit the geometric arrangement and shape flexibility of these components, as they are typically embedded in the same plane, restricting design freedom and requiring intricate manufacturing processes.
Innovation Solution
A method involving a three-layer structure where the heating element and cooling channel are in different planes, allowing for easier rolling and diffusion bonding, with the option to recess the second core layer to prevent material displacement and optimize space utilization, enabling more flexible geometric arrangements and shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If heating elements and cooling channels are embedded in the same plane of the core layer, then the manufacturing process can be simplified, but the geometric arrangement and shape flexibility of these components is limited
Solution Approach 1:
The patent applies dimensionality change by separating heating elements and cooling channels into different planes within the core layer. The first core layer contains heating elements while the second core layer contains cooling channels, creating a three-dimensional arrangement that provides geometric flexibility without complicating the manufacturing process. This spatial separation allows independent optimization of heating and cooling component shapes and positions.
2Manufacturing precision
If recesses are provided in the core layer for embedding heating elements, then the heating elements can be properly positioned, but the manufacturing process becomes more complex and air gaps may remain
Solution Approach 1:
The patent merges the heating element embedding process with the diffusion bonding process. By placing heating elements between the first and second core layers before bonding, the elements are automatically positioned and secured during the diffusion bonding operation. This eliminates the need for separate recess creation and embedding steps, reducing manufacturing complexity while ensuring precise positioning without air gaps.
Solution Approach 2:
The heating elements are preliminarily positioned between the core layers before the diffusion bonding process occurs. This preliminary placement ensures correct positioning is achieved before the layers are bonded together, preventing the need for subsequent adjustment operations and ensuring complete elimination of air gaps through the bonding process.
3Adaptability or versatility
If the core layer is produced from two diffusion-bonded core layer layers, then heating elements can be embedded, but the production process becomes relatively complicated
Solution Approach 1:
The diffusion bonding process serves multiple functions simultaneously: it bonds the first and second core layers together, embeds the heating elements in the first core layer, and creates the final composite structure. This multi-functionality eliminates the need for separate embedding operations, reducing production process complexity while maintaining the capability to embed heating elements.
4Device complexity
If heating wires and cooling channels are arranged in the same central plane, then the structure is simpler, but the choice of placement and shape is restricted
Solution Approach 1:
The patent uses dimensionality change to arrange heating wires and cooling channels in different central planes. The heating elements are positioned in the first core layer's central plane while cooling channels are positioned in the second core layer's central plane. This vertical separation provides freedom in choosing placement and shapes for both heating and cooling components without increasing structural complexity, as the multi-layer structure naturally accommodates multiple planes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach simplifies the manufacturing process, allows for greater design freedom in arranging heating elements and channels, and results in an extremely flat composite metal object with enhanced heat transfer and cooling capabilities.
Implementation Method 1
heat pretreating the core layers and the cover layers at a temperature above the recrystallization temperature of the aluminum or aluminum alloy, but below the melting point of the aluminum
Implementation Method 2
at least the cover layers and the core layers form a mutual diffusion bond in the area of their mutually contacting sides and are thereby metallurgically bonded
Implementation Method 3
pressing the core layers and the cover layers together by rolling in order to embed the heating element(s) in the two core layers and to effect a thickness reduction
Data Source
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AI summary
A description is given of a method for producing a composite metal article (10) with an embedded heating element (30) and a composite metal article (10) produced thereby. The composite metal article (10) has an at least two-ply core layer (20) of aluminium or an aluminium alloy and two outer layers (14, 15) of metal, for example of stainless steel. Arranged between one (15) of these outer layers and one (12) of the core layer plies is a third core layer ply (13) of aluminium or an aluminium alloy, which has a channel (16) for cooling fluid. The third core layer ply (13) is diffusion-connected to the second core layer ply (12) and the one (15) of the outer layers. The two core layer plies (11, 12) and the other outer layer (14) are likewise diffusion-connected to one another. The first and second core layer plies (11, 12) have a heating element (30) embedded in them and form a heating plate (22). The third core layer ply (13), which contains the channel (16), forms a cooling plate (24). With respect to an imaginary centre plane (26) of the core layer (20), the channel (16) lies on one side of the centre plane (26) and the heating element (30) lies on the other side of the centre plane (26).