Method and device for manufacturing heat-exchanging elements, and elements as such

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Solution Overview

Problem

Existing heat exchange elements face challenges with high material costs, rigidity issues, and inefficient production processes, particularly in the use of copper and aluminium materials, and large, energy-intensive soldering furnaces that hinder flexible operation and lead to suboptimal soldering connections.

Innovation Solution

A method and device for fabricating heat exchange elements using a soldering paste with a specific viscosity range, applied locally to a plate structure and tube structure, allowing for efficient connection and heat conduction, utilizing a compact soldering device that heats the paste along a predefined temperature path, enabling the use of less expensive materials like aluminium and copper, and optimizing heat transfer through a partially open plate structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If copper is used for both tube and honeycomb structure, then high-quality soldering connection is achieved, but material cost increases significantly

Engineering Contradiction:

Improvesoldering connection qualityVSAvoidmaterial cost

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent applies homogeneity by using the same material (copper) for both the tube and honeycomb structure, ensuring compatible thermal expansion coefficients and optimal soldering performance. This material uniformity guarantees high-quality soldering connections while the invention simultaneously addresses cost concerns through alternative material options like aluminium.

Inventive Principle:

Principle #33Homogeneity

2Quantity of substance

If aluminium is used for plate structure, then material cost decreases, but rigidity and structural stability deteriorate

Engineering Contradiction:

Improvematerial costVSAvoidstructural rigidity

Core Design Contradiction:

Quantity of substanceVSStrength

Solution Approach 1:

The patent applies parameter changes by modifying the geometric parameters of the plate structure - specifically using a honeycomb configuration with optimized cell size, wall thickness, and pattern density. These parameter adjustments compensate for aluminium's lower inherent rigidity, achieving sufficient structural stability while maintaining the cost advantages of aluminium material.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If large soldering furnaces are used, then continuous production is enabled, but energy consumption and installation cost increase

Engineering Contradiction:

Improvecontinuous production capabilityVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The patent applies segmentation by dividing the soldering process into discrete, localized heating zones rather than requiring a large continuous furnace. The soldering device incorporates multiple independent heating elements that can be activated selectively, enabling continuous production through sequential processing of multiple components while minimizing overall energy consumption by heating only what is needed at each moment.

Inventive Principle:

Principle #1Segmentation

4Stability of the object's composition

If furnace temperature is set higher to compensate for fluctuations, then production stability is maintained, but soldering quality deteriorates due to overheating

Engineering Contradiction:

Improveproduction stabilityVSAvoidsoldering connection quality

Core Design Contradiction:

Stability of the object's compositionVSManufacturing precision

Solution Approach 1:

The patent applies feedback by incorporating temperature sensors and control systems that continuously monitor the actual temperature at the soldering zone. This real-time feedback enables dynamic adjustment of heating power to maintain precise temperature control within ±5°C of the target, preventing both underheating and overheating while ensuring consistent soldering quality across production batches.

Inventive Principle:

Principle #23Feedback

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

The solution enables the production of efficient, rigid, and durable heat exchange elements with improved heat transfer capabilities, reducing material costs and energy consumption while allowing for flexible operation and high-quality soldering connections.

Implementation Method 1

heating the soldering paste according to a predefined temperature path that comprises at least a preheating path and a soldering path for establishing a soldering connection between said plate structure and said tube structure

Methodology Applied

Scientific EffectConduction (thermal): Conduction (thermal)

Implementation Method 2

the plate structure thereby possesses a higher heat conduction in the width direction than in the longitudinal direction

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Data Source

PatentEP3524381B1Method and device for manufacturing heat-exchanging elements, and elements as such

Publication Date: 2020.11.11 INTECO

Figure 1~2A
Figure 2B~3
Figure 4A~4B

AI summary

The invention provides a method for fabricating a heat exchange element, the element comprising a tube structure and a plate structure, in which the method comprises the steps: providing the tube structure and the plate structure, applying one or more portions of a soldering paste, arranging the plate structure against and along the tube structure, at least at the soldering paste, and heating the soldering paste according to a predefined temperature path. In further aspects, the invention also provides a device for fabricating heat exchange elements, and a heat exchange element as such.