Heat Exchanger Panel Assembly With Flexible Alignment Features
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Solution Overview
Problem
Existing HVAC systems face inefficiencies and high costs due to the design and manufacturability challenges of panels used in three-way heat exchangers, which are crucial for heat and moisture transfer in air treatment systems.
Innovation Solution
A method of assembling multilayer panels for heat exchangers involves positioning a frame with header sections and a middle section, attaching heat exchange sheets with controlled alignment using flexures, and welding to form welds that envelop fluid and header areas, enhancing alignment and manufacturability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional rigid alignment methods are used during panel assembly, then alignment precision may be maintained, but manufacturing complexity and cost increase due to additional fixtures and adjustment mechanisms
Solution Approach 1:
The patent changes the physical state of the alignment feature from rigid to flexible by incorporating a flexure element. This allows the alignment feature to deform elastically during assembly, automatically accommodating misalignments between the frame and heat exchange sheet without requiring complex adjustment mechanisms or fixtures.
Solution Approach 2:
The flexible alignment feature performs the alignment function autonomously through its elastic deformation capability. The flexure element self-adjusts to compensate for dimensional variations and positioning errors, eliminating the need for external alignment fixtures, clamps, or skilled manual adjustment during the welding process.
2Ease of manufacture
If flexible alignment features are incorporated into the panel design, then ease of assembly and manufacturing cost are improved, but structural rigidity may be compromised
Solution Approach 1:
The alignment feature is segmented into distinct functional zones: a flexible portion containing the flexure element for absorption of misalignment, and a rigid portion that maintains structural integrity and transmits load. This segmentation allows each zone to perform its specific function optimally without compromising the other.
Solution Approach 2:
The patent applies local flexibility only where needed for alignment compensation, while maintaining global structural rigidity. The flexure element is localized to the alignment feature, whereas the frame, heat exchange sheet, and weldment maintain their structural strength. This localized application of flexibility preserves overall structural integrity while enabling easy assembly.
Data Source
AI summary
A method of assembling a multilayer panel for use in a heat exchanger includes positioning a frame on a work platform, the frame having two header sections and a middle section, the middle section defining a heat transfer fluid area and each header section defining a header area. The method also includes positioning a heat exchange sheet on the frame across the middle section and each header section, welding the heat exchange sheet to the frame to form a middle weld enveloping the heat transfer fluid area and two outer welds each enveloping a corresponding one of the header areas, and controlling alignment between the frame and the heat exchange sheet during welding.