Metal Plate Embedded Heating Element Diffusion Bonding
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Solution Overview
Problem
Existing methods for producing metal plates with embedded heating elements often result in air gaps between the plate bodies, which impede thermal conductivity, limiting the overall thermal performance and application range of the metal plates.
Innovation Solution
The method involves thermally pre-treating aluminum or aluminum alloy plate bodies to their re-crystallization temperature and then rolling them to embed the heating elements, creating a bilateral diffusion bond that eliminates air gaps and ensures a positively bonded connection over the entire surface, thereby enhancing thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If plate bodies are compressed and connected by rivets or welding seams, then mechanical connection is achieved, but air gaps remain at the boundaries affecting thermal conduction
Solution Approach 1:
The patent merges the mechanical connection function and thermal conduction function into a single diffusion bonding interface. By thermally pre-treating the plate bodies to recrystallization temperature and then compressing them, the aluminum layers diffuse into each other, creating an integral bond that simultaneously provides mechanical strength and eliminates air gaps for continuous thermal conduction.
Solution Approach 2:
The aluminum layer acts as an intermediary material between the plate bodies. This aluminum layer is thermally pre-treated and then compressed to create a diffusion bond that mediates both mechanical connection and thermal conduction, replacing the need for separate rivets or welding seams that would create air gaps.
2Strength
If high-temperature resistant plastic material is used to interconnect plate bodies, then connection is achieved, but thermal conduction is impaired due to material properties
Solution Approach 1:
The patent changes the temperature parameter by thermally pre-treating the plate bodies to recrystallization temperature before compression. This temperature change enables the aluminum layers to become sufficiently soft and reactive to diffuse into each other, creating a metallurgical bond that provides both mechanical strength and continuous thermal conduction, unlike plastic materials that would impede heat flow.
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 approach results in a metal plate with improved thermal conductivity and a wider range of applications by eliminating air gaps and ensuring a strong, integral bond between the plate bodies and the heating elements, allowing for efficient heat transfer and reduced thickness without the need for recesses or additional binding materials.
Implementation Method 1
thermally pre-treated at a temperature at least identical to the re-crystallisation temperature of the aluminium or the aluminium alloy
Implementation Method 2
pressed by rolling to effect the embedding of the or each heating element in the plate bodies and a reduction of the thickness of the layers during which the layers enter into a bilateral diffusion bond
Data Source
AI summary
A description is given of a process for producing a metal plate having at least one embedded heating element and of the metal plate produced by the process. The heating element is arranged between two plate bodies, and the heating element is embedded in the plate bodies by rolling with material displacement. The adjacent sides of the plate bodies have a layer of aluminum or an aluminum alloy. After a heat pre-treatment at the re-crystallization temperature of the aluminum or the aluminum alloy, the plate bodies are pressed against one another to bring about a reduction in thickness, with which the plate bodies form a diffusion bond with one another and are integrally bonded to one another over the entire surface area thereof to form the metal plate to be produced. The process produces a metal plate as a whole with better thermal conductivity and a broader spectrum of use.