Die-Cast Heat Exchanger for Continuous Flow Fluid Heating
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Solution Overview
Problem
Current heating devices for continuous flow fluids, such as those used in coffee machines, face inefficiencies in heat exchange due to incomplete joining of components during brazing, high production waste, and complex production processes, particularly with extrusion and low-pressure die-casting methods.
Innovation Solution
A device with a metal body incorporating a conduit and heating elements, featuring slits or holes to ensure perfect joining and compensate for thermal expansion, produced using high-pressure die-casting to enhance heat exchange efficiency and simplify production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If brazing is used to join the steel pipe and aluminium body, then the components can be connected, but the joining is incomplete and production waste is high
Solution Approach 1:
The patent merges the steel pipe and aluminium body into a single integrated component through high-pressure die-casting, eliminating the need for separate brazing operations. The steel pipe is embedded directly into the aluminium body during casting, ensuring complete joining without material waste from brazing processes.
Solution Approach 2:
The patent replaces the thermal-brazing process with a mechanical high-pressure die-casting process. Instead of using heat and filler metal to join components, the aluminium body is cast under high pressure to encapsulate the steel pipe, creating a stronger and waste-free connection.
2Strength
If long continuous longitudinal grooves are present in the body, then the heating element can be anchored, but a long portion of the heating element is not in contact with the body reducing heat exchange
Solution Approach 1:
The patent segments the heating element contact arrangement by using multiple discrete anchoring points (projections) distributed along the heating element rather than one long continuous groove. This segmentation ensures that the heating element is securely anchored while maintaining thermal contact along its entire length through the distributed projection structure.
3Ease of manufacture
If extrusion method is used to produce the device, then the components can be manufactured, but the production process is complex and time-consuming
Solution Approach 1:
The patent combines multiple manufacturing steps into a single high-pressure die-casting operation. The aluminium body, steel pipe embedding, and internal cavity formation are all achieved in one casting process, eliminating the separate steps required in extrusion methods and significantly increasing production speed.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution achieves improved heat transmission, reduced thermal inertia, and increased production efficiency by ensuring complete contact between components and integrating thermostat and sensor platforms directly into the aluminum alloy body, resulting in rapid and homogeneous heating.
Implementation Method 1
a heating element, distinct from the body and from the conduit, shaped so as to have two longitudinal stretches that longitudinally flank the conduit along two sides... whereby the heat generated by the heating element can be transmitted to the liquid in the conduit by means of conduction
Implementation Method 2
the heat generated by the heating element can be transmitted to the liquid in the conduit by means of conduction
Implementation Method 3
the body is provided with a plurality of slits or holes, distinct and axially separated from each other, having a depth equal to the thickness of the wall... at least two first slits of said plurality of slits or holes are on the conduit and at least two second slits of said plurality of slits or holes are on each stretch of the single heating element
Data Source
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AI summary
The invention provides a device (200, 300, 400) for heating a continuous flow fluid. Said device (200, 300, 400) consists of a steel conduit (3, 3', 3") through which the fluid to be heated flows and of at least one sheathed resistor (2, 2c, 2d, 2e, 2f) that is parallel to the steel conduit (3, 3', 3") and that is in thermal contact therewith. The steel conduit (3, 3', 3") and the at least one heating element (2, 2c, 2d, 2e, 2f) are incorporated in a die-casting element made of an aluminium alloy.