Heat Plate Sealing With Segmented Welding Beads
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Solution Overview
Problem
Traditional heat plate manufacturing processes face issues with airtightness and structural strength due to inadequate sealing and deformation of thin, light cases, leading to potential leakage and compromised heat conductivity.
Innovation Solution
A heat plate sealing method involving a welding frame with inner and outer track welding beads, where solder is applied between the beads to enhance sealing, and thermal melting is used to secure the plates, with a capillary tissue for additional support and airtightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single welding bead is used to seal the heat plate, then the manufacturing process is simple, but the airtightness and structural strength are insufficient
Solution Approach 1:
The welding bead is divided into multiple segments (first welding bead, second welding bead, third welding bead) arranged in a staggered pattern around the circumferential edge. This segmentation provides multiple sealing paths, ensuring that if one welding bead fails, the others maintain the airtight seal, thereby significantly improving reliability without requiring a completely complex structure.
Solution Approach 2:
The welding beads are arranged not only in different angular positions but also at different radial distances from the center (first at radius R1, second at R2, third at R3 where R1 < R2 < R3). This multi-dimensional arrangement creates a redundant sealing system that enhances airtightness while maintaining reasonable structural complexity.
2Weight of moving object
If the heat plate case is made extremely light and thin, then the weight is reduced, but the structural strength and resistance to deformation are compromised
Solution Approach 1:
The support structure is segmented into multiple welding beads positioned at different locations and radii. This distributed support system provides enhanced structural reinforcement without requiring the case material itself to be thicker, allowing the heat plate to remain lightweight while gaining strength through the distributed welding pattern.
Solution Approach 2:
The multiple welding beads are positioned beforehand to provide preemptive structural support and distribute mechanical stresses before they can cause deformation. The staggered arrangement ensures that forces are distributed across multiple reinforcement points, preventing localized deformation in the thin-walled structure.
3Strength
If the circumferential edge is reinforced to prevent deformation, then structural strength is improved, but the airtightness may be compromised due to welding imperfections
Solution Approach 1:
The circumferential edge sealing is divided into multiple discrete welding beads positioned at different angular locations and radii. This segmentation creates multiple independent sealing paths, so that even if one welding bead has imperfections, the other beads maintain the airtight seal, thereby ensuring reliability while providing structural reinforcement.
Solution Approach 2:
The welding beads are strategically positioned beforehand to provide both structural reinforcement and sealing function. The staggered arrangement is pre-planned to ensure optimal distribution of mechanical strength and airtightness, addressing both requirements simultaneously before the actual sealing process.
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 method strengthens the sealed structure and ensures airtightness by using a layered welding approach, reducing the likelihood of leakage and improving heat conductivity.
Implementation Method 1
The bottom plate and the cover plate are sealed together by conducting thermal melting on the solder
Implementation Method 2
a liquid is disposed in a sealed plate-form chamber to efficiently transfer heat by a phase transition, of the liquid, between a vapor phase and a liquid phase
Data Source
AI summary
A heat plate sealing method and structure thereof includes a) providing a bottom plate and a cover plate engaging with each other; b) providing a welding frame; c) disposing the welding frame between the bottom plate and the cover plate; d) placing solder on the welding frame; e) sandwiching the welding frame having the solder thereon between the bottom plate and the cover plate; and f) conducting thermal melting on the solder to seal the bottom plate and the cover plate. Therefore, a sealing structure is strengthened and the airtightness during a sealing process is enhanced.