Heat Exchanger Lamination With Thermoplastic Resin Joining
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Solution Overview
Problem
The existing heat exchangers face challenges in productivity due to high difficulty in sealing the outer peripheral wall and wick forming the flow path, leading to long joining process times and limited open time, which hinders efficient manufacturing.
Innovation Solution
A method involving a pre-joining process with a laminated body of a surface sheet and flow path forming sheet using a solid joining agent composed of amorphous thermoplastic resin, such as thermoplastic epoxy resin or phenoxy resin, joined by heating and pressurizing under specific conditions to form a heat exchanger with high joining strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If diffusion joining is used to seal the outer peripheral wall and wick, then joining strength is achieved, but the degree of difficulty increases and production efficiency decreases
Solution Approach 1:
A solid joining agent is introduced as an intermediary material between the outer peripheral wall and wick. This joining agent facilitates the bonding process by providing a medium that enables joining without the complexity of diffusion joining, thereby reducing manufacturing difficulty while maintaining joining strength.
Solution Approach 2:
The invention changes the joining parameters by using a solid joining agent with specific properties (amorphous thermoplastic resin with controlled heat of fusion and epoxy equivalent). By adjusting these material parameters, the joining process becomes simpler and more suitable for mass production while achieving adequate bond strength.
2Reliability
If conventional joining methods are used, then joining is achieved, but joining process time is long and productivity is low
Solution Approach 1:
The solid joining agent utilizes phase transition (melting and solidification) to achieve joining. The joining agent melts during the joining process to facilitate bonding, then solidifies to create a strong bond. This phase transition mechanism enables rapid joining without long curing times, significantly improving productivity while maintaining joining reliability.
Solution Approach 2:
The invention replaces conventional mechanical or thermal joining methods with a chemical-physical joining mechanism using the solid joining agent. This substitution allows for faster joining cycles and improved production efficiency while ensuring reliable bonds between components.
3Speed
If short open time joining agent is used, then joining speed is fast, but flexibility in manufacturing process is reduced
Solution Approach 1:
The solid joining agent provides dynamic characteristics by maintaining its bonding capability over an extended open time period. This allows the manufacturing process to be flexibly adjusted without compromising joining speed, enabling workers to complete assembly tasks at optimal pacing while maintaining high productivity.
4Productivity
If amorphous thermoplastic resin with low heat of fusion is used, then joining process time is reduced, but material selection is more restricted
Solution Approach 1:
The invention employs composite material design by combining amorphous thermoplastic resin with specific epoxy resins. This composite approach creates a joining agent that meets the heat of fusion requirements for fast joining while providing sufficient material flexibility and selection range for different application requirements.
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 significantly improves productivity by reducing the joining process time and extending the open time, while ensuring high joining strength and preventing electrolytic corrosion between dissimilar metal members.
Implementation Method 1
a joining process of joining the surface sheet and the flow path forming sheet by heating and pressurizing the laminated body to melt the solid joining agent
Implementation Method 2
heating and pressurizing the laminated body to melt the solid joining agent
Implementation Method 3
an amorphous thermoplastic resin... heat of fusion of the amorphous thermoplastic resin is 15 J/g or less
Data Source
AI summary
The method for producing a heat exchanger includes: a before-joining step in which prepared is a stack in which a surface sheet, a solid joining material comprising, as a main component, an amorphous thermoplastic resin which is at least one resin selected from among thermoplastic epoxy resins and phenoxy resins, and a channel formation sheet having a channel in a surface thereof facing the surface sheet have been arranged in this order; and a joining step in which the stack is heated and pressed to melt the solid joining material and join the surface sheet to the channel formation sheet. The amorphous thermoplastic resin has an epoxy equivalent of 1,600 or greater, or the amorphous thermoplastic resin contains no epoxy group and has a heat of fusion of 15 J/g or less.