Heat Exchanger Corner Sealing Using Inflatable Unvulcanized Rubber
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Solution Overview
Problem
Existing heat exchangers face challenges in maintaining airtightness at corner portions of laminated heat transfer sheets, especially when exposed to external forces, and cannot use silicone-based materials due to coating defects in environments like painting factories.
Innovation Solution
Inserting unvulcanized rubber mixed with a vulcanizing agent into the clearance between corner portions of the heat exchanger and corner members, which inflates and vulcanizes upon heating to secure airtightness without applying excessive pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a caulking agent containing silicone is used for airtight holding, then airtightness is improved, but coating defects occur on painting surfaces
Solution Approach 1:
The invention extracts and removes silicone from the caulking agent formulation, replacing it with alternative materials (fluorocarbon rubber-based compounds) that provide airtightness without causing coating defects. This directly resolves the contradiction by eliminating the harmful substance while maintaining the sealing function.
Solution Approach 2:
The invention changes the chemical composition parameters of the caulking agent by substituting silicone with fluorocarbon rubber-based materials and adjusting the solvent content to 20-60%. This parameter change maintains airtightness performance while eliminating the harmful coating effects associated with silicone.
2Ease of operation
If a caulking agent with high solvent content is used, then ease of application is improved, but localized necking occurs reducing airtight effectiveness
Solution Approach 1:
The invention optimizes the solvent content parameter to a specific range of 20-60%, balancing the competing requirements. This parameter setting ensures sufficient fluidity for easy application while preventing excessive solvent evaporation that would cause localized necking and compromise airtightness.
3Reliability
If a fluorocarbon rubber sponge is inserted for pressurization, then airtight holding is improved, but the heat exchange layered body deforms due to low strength
Solution Approach 1:
The invention replaces the mechanical pressurization method (using fluorocarbon rubber sponge insertion) with a chemical-curing system. The caulking agent cures in place through chemical reaction, providing airtightness without requiring external mechanical pressure that would deform the weak heat exchange layered body.
Solution Approach 2:
The caulking agent performs self-service by curing autonomously within the heat exchange layered body structure. The material sets and hardens through chemical reaction without requiring external pressurization equipment or mechanical intervention, thereby avoiding deformation of the delicate layered structure.
4Reliability
If heating and pressuring are applied simultaneously for vulcanization, then adhesion is improved, but the heat transfer sheets deform due to excessive external force
Solution Approach 1:
The invention replaces the mechanical pressuring system with a chemical-curing system. The vulcanizing agent cures the rubber material through chemical reaction without requiring external mechanical pressure, thereby achieving strong adhesion while preventing deformation of the heat transfer sheets.
Solution Approach 2:
The invention changes the curing mechanism from mechanical-thermal (pressuring + heating) to chemical-thermal (vulcanization reaction + heating). This parameter change in the curing process allows adhesion to be achieved through chemical bonding rather than mechanical compression, preserving the shape integrity of the heat transfer sheets.
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 ensures easy and secure airtight holding at the corner portions of heat exchangers, preventing leaks and coating defects, even in environments where silicone cannot be used, while maintaining the structural integrity of the heat transfer sheets.
Implementation Method 1
Inserting unvulcanized rubber mixed with a vulcanizing agent into the clearance between corner portions of the heat exchanger and corner members, which inflates and vulcanizes upon heating to secure airtightness
Implementation Method 2
which inflates and vulcanizes upon heating
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present invention provides a heat exchanger. The heat exchanger can exchange heat at a place where a material containing silicone cannot be used. [Means for Solution] The heat exchanger of the present invention has a heat exchange layered body which is secured by a corner member 12, a top plate 13, a sole plate 14. An unvulcanized rubber 18 in which a vulcanized agent is mixed is inserted into a connecting portion between the corner member 12 and a corner portion of the heat exchange layered body. The unvulcanized rubber 18 is made to foam and inflate by heating. Thereby, the heat exchanger has a high airtightness in a short time in a process of its manufacturing and can be used in a painting factory, etc. where a material including silicon cannot be used.