Diffusion Welded Heat Exchanger Modules for Corrosion Resistance
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Solution Overview
Problem
Current heat exchanger systems, particularly compact plate exchangers, face challenges in widespread industrial adoption due to manufacturing inefficiencies and limitations in corrosion resistance, sealing, thermal conductivity, and pressure handling.
Innovation Solution
A method for manufacturing heat exchanger systems involving diffusion welding of metal conduits with a filling matrix and plates, along with metal connection elements, which enhances corrosion resistance, sealing, thermal conductivity, and pressure handling capabilities, while allowing for modular design and easy production of various geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional manufacturing methods (welding/brazing) are used to assemble heat exchanger components, then assembly strength and sealing are achieved, but corrosion resistance deteriorates due to welding/brazing contact with corrosive fluids
Solution Approach 1:
The patent replaces conventional welding/brazing mechanical joining methods with diffusion bonding, a solid-state diffusion process that joins metal surfaces at atomic level without melting or filler materials. This substitution eliminates corrosion-prone weld zones while maintaining assembly strength and sealing integrity.
Solution Approach 2:
The patent changes the manufacturing parameters from conventional welding temperatures and processes to diffusion bonding parameters (controlled temperature, pressure, and time in a protective atmosphere). This parameter change enables joining without the harmful effects of welding/brazing on corrosion resistance.
2Strength
If metal conduits are directly assembled without a filling matrix, then manufacturing simplicity is maintained, but thermal conductivity and structural integrity deteriorate under high pressure
Solution Approach 1:
The patent introduces a metal filling matrix that creates a composite structure combining conduits, plates, and filling material. This composite construction provides enhanced structural integrity, thermal conductivity, and pressure handling capability while maintaining modular assembly through diffusion bonding of all components.
3Reliability
If welding/brazing processes are used to join conduits with plates, then assembly strength is achieved, but sealing performance deteriorates due to potential leakage paths
Solution Approach 1:
The patent replaces welding/brazing with diffusion bonding, a solid-state process that creates seamless atomic-level joints between conduits, plates, and filling matrix. This eliminates potential leakage paths at joints while maintaining assembly strength, achieving superior sealing performance without conventional welding complexities.
4Use of energy by moving object
If conventional heat exchanger designs are used, then manufacturing simplicity is maintained, but thermal inertia and heat absorption capacity are insufficient for exothermic reactions
Solution Approach 1:
The patent employs a metal filling matrix within the modular structure to increase thermal mass and thermal inertia. This composite construction provides enhanced heat absorption capacity for exothermic reactions while maintaining the modular design that enables flexible configuration and manufacturing.
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 method results in heat exchanger systems that are highly resistant to corrosion, provide excellent sealing and thermal conductivity, can withstand high pressures, and offer significant thermal inertia, ensuring reliability and safety, while being cost-effective and modular.
Implementation Method 1
processing said assembly so as to obtain diffusion welding of the conduits with said metal filling matrix, with said plates, and with the two metal connection elements
Data Source
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AI summary
The invention relates to a method for making a heat exchanger system including at least one module (1) through which extends a row of channels, wherein the module is made as follows: forming an assembly (4) including, in parallel, a plurality of metal ducts (10) each having an inner space defining one of the fluid circulation channels, the ducts being arranged between two metal plates (6, 6), the gaps defined by the directly consecutive ducts and the metal plates being filled by a metal filling matrix (8), wherein the assembly also includes connection members (20) for the ducts; and processing the assembly (4) so as to obtain a diffusion welding of the ducts (10) with the matrix (8), the plates and the members (20).