Energy Exchanger Core Assembly Using Cut Plates and Blanking Members
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Solution Overview
Problem
The manufacturing of energy exchanging devices like microchannel heat exchangers and fuel cells is complex and costly due to processes such as photochemical etching and diffusion bonding, which are time-consuming and expensive, limiting their use in industrial setups requiring low-cost solutions.
Innovation Solution
A method involving through cut machining to define flow channels in plates, stacking with blanking members to form fluid flow paths, and bonding using processes like vacuum brazing to create an energy exchanging core with defined inlet and outlet ports, reducing manufacturing time and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If photochemical etching and diffusion bonding processes are used to manufacture energy exchanging devices, then manufacturing precision and reliability are improved, but manufacturing time and cost increase significantly
Solution Approach 1:
The patent replaces photochemical etching (chemical process) with mechanical drilling or punching operations to create flow channels in plates. This substitution eliminates the need for complex chemical etching processes while achieving the required precision for burr-free surfaces through controlled mechanical means, thereby significantly reducing manufacturing time
Solution Approach 2:
The patent extracts and eliminates the diffusion bonding step from the manufacturing process by using alternative joining methods such as mechanical fastening, welding, or adhesive bonding. This removal of the time-consuming diffusion bonding process maintains joint integrity while reducing overall manufacturing time and cost
2Manufacturing precision
If photochemical etching and diffusion bonding processes are used to manufacture energy exchanging devices, then manufacturing precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent employs cost-effective materials and processes such as standard metal plates with conventional flow channels instead of expensive specialized materials requiring photochemical etching. The design uses readily available components and standard manufacturing techniques that reduce material and processing costs while maintaining sufficient joint integrity for industrial applications
Solution Approach 2:
The patent replaces expensive diffusion bonding with more economical joining methods such as arc welding, gas welding, or mechanical fastening systems. These alternative joining processes achieve adequate joint strength and integrity at lower cost and with simpler equipment requirements, making the manufacturing process more economically viable
3Reliability
If complex manufacturing processes are used, then device reliability is improved, but device complexity increases
Solution Approach 1:
The patent divides the manufacturing process into distinct, independent stages: plate preparation with flow channels, stacking/assembly of multiple plates, and joining operations. This segmentation allows each stage to be optimized separately using simple, reliable processes rather than one complex integrated process, reducing overall manufacturing complexity while maintaining device reliability through controlled quality at each stage
Solution Approach 2:
The patent performs preliminary actions such as pre-drilling flow channels, pre-cutting plates to size, and pre-positioning components before final assembly and joining. These preliminary preparation steps simplify the main manufacturing operations and reduce the complexity of the critical joining and assembly processes, ensuring device reliability through proper preparation
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 method reduces production time and cost, enabling the use of energy exchanging devices in industrial settings by providing a more efficient and economical manufacturing process for compact, high-performance energy exchanging devices.
Implementation Method 1
defining a plurality of through slots in a major surface of a plurality of plates by a through cut machining process... wherein the through cut machining process includes at least one of a laser machining
Implementation Method 2
the through cut machining process includes at least one of a laser machining, wire electrical discharge machining (wire EDM)
Implementation Method 3
the through cut machining process includes at least one of a laser machining, wire electrical discharge machining (wire EDM), Waterjet cutting
Implementation Method 4
bonding the at least one blanking member with the major surface of each of the plurality of plates, to form an energy exchanging core
Implementation Method 5
Subsequent to forming the flow channels, the plates are stacked up 12 and are fixed by diffusion bonding to form an energy exchanger core 13
Data Source
AI summary
The present disclosure discloses a method (200) of manufacturing an energy exchanging device (100). The method includes defining a plurality of through slots (14, 17) in a plurality of plates (2) by a through cut machining process, in which, each of the plurality of through slots define a flow channel. The method further includes stacking the plurality of plates (2) with at least one blanking member (24) positioned therebetween. Such stacking of the plurality of plates (2) forms a plurality of fluid flow paths about the plurality of through slots. The method further includes bonding the at least one blanking member with the plurality of plates, to form an energy exchanging core (1). The method further includes defining at least two inlet ports (45a, 45b) and at least two outlet ports (46a, 46b) in the core, for flow of fluid along the plurality of fluid flow paths within the core.