Heat Exchanger Flow-Through Component Bonding With Hot-Cold Pressing
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Solution Overview
Problem
The production of heat exchanger components involves complex and costly processes, particularly in joining metal components to form fluid channels, which can be simplified and made more cost-effective.
Innovation Solution
A method involving gluing a metal base plate to a metal channel plate with an adhesive, clamping, heating, and cooling to create a durable material bond, using a hot press for heating and a cold press for curing the adhesive, with elastic elements to compensate for tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal components are joined by soldering in a complex process, then strong material bond is achieved, but production cost and process complexity increase
Solution Approach 1:
The patent changes the bonding mechanism from soldering to adhesive bonding with controlled temperature and pressure parameters. The adhesive layer is heated to melt and distribute evenly, then cooled to cure, transforming the bonding process into a thermally-controlled parameter change process that simplifies production while maintaining bond strength
Solution Approach 2:
The patent replaces the mechanical soldering process with a thermal-adhesive bonding system. Instead of using solder and complex joining mechanisms, the invention uses an adhesive layer that is melted and cured through controlled heating and cooling, substituting mechanical complexity with thermal process control
2Reliability
If adhesive layer is heated to melt and distribute evenly, then adhesion durability is improved, but energy consumption increases
Solution Approach 1:
The patent applies preliminary action by pre-heating the adhesive layer to its melting point before pressing the components together. This ensures the adhesive is in optimal liquid state for distribution and bonding, improving adhesion durability while minimizing the total energy required by having the heating phase prepared in advance
Solution Approach 2:
The bonding process uses periodic action with distinct heating, holding, and cooling phases. The adhesive is heated to melt, held at temperature for even distribution, then cooled to cure. This periodic thermal cycle optimizes energy usage by maintaining temperature only during the critical bonding phase rather than continuous heating
3Manufacturing precision
If elastic elements are used to compensate for tolerances, then bonding precision is improved, but device complexity increases
Solution Approach 1:
The patent applies local quality by using elastic elements only at specific contact points or regions where tolerance compensation is needed, rather than throughout the entire press mechanism. This localized approach improves bonding precision at critical interfaces while minimizing the overall device complexity
Solution Approach 2:
The elastic elements serve as intermediaries between the press mechanism and the components being bonded. They absorb tolerance variations and provide consistent contact pressure, acting as a mediating layer that improves bonding precision without requiring the entire press system to be highly precise
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 simplifies the production of heat exchanger components by achieving strong and durable adhesion between the base and channel plates, enhancing the material bond's durability and efficiency while reducing production costs.
Implementation Method 1
the adhesive is heated in the at least one bonding region between the base plate and the channel plate to obtain a material bond
Implementation Method 2
The pressure in combination with heating the base plate and channel plate melts the adhesive layer formed by the glue
Implementation Method 3
The glue is then cured when the components are cooled
Implementation Method 4
The glue is then cured when the components are cooled
Implementation Method 5
the tolerances resulting from unevenness of the base plate and channel plate, as well as tolerances in the components of the hot press, can be compensated for by this elastic element
Data Source
AI summary
A method for producing a component for a heat exchanger through which fluid can flow is provided. A base plate is provided, on which there is an adhesive layer formed by glue. A channel plate is placed on the surface of the base plate such that the channel plate is spaced apart from the base plate in at least one channel region to delimit at least one fluid channel, and bears on the adhesive layer in at least one bonding region to obtain a material bond with the base plate The channel plate and base plate are clamped together in and by a press, such that a material bond is formed between the base plate and the channel plate when the adhesive layer is heated in the at least one bonding region. The base plate and channel plate are placed in a cold press such that the adhesive layer that was heated in the hot press is cooled while the base plate is clamped against the channel plate.