Method for manufacturing a heat exchanger module with at least one fluid circulation circuit
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Solution Overview
Problem
Current methods for manufacturing heat exchangers with multiple fluid circuits using different materials face limitations in achieving optimal mechanical and thermal performance, particularly in complex geometries and in overcoming defects like porosity and mechanical stress, while also being cost-effective.
Innovation Solution
A method involving the production of heat exchanger modules with a metal casing and fluid tubes, where fusible metals or alloys with lower melting points are introduced and melted to fill the module, followed by Hot Isostatic Compression to eliminate defects and enhance properties, allowing for complex geometries and improved thermal and mechanical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple different materials are used to optimize both mechanical strength and thermal performance, then the thermal and mechanical properties are improved, but the manufacturing complexity and difficulty of joining materials increase
Solution Approach 1:
The patent combines multiple different materials (e.g., metal casing, fusible metal, polymer material) into a single integrated heat exchanger module through a multi-step manufacturing process. The metal casing provides structural strength, the fusible metal provides thermal conductivity, and the polymer material provides chemical resistance, creating a composite structure that achieves optimal thermal and mechanical performance while managing manufacturing complexity through systematic process integration.
Solution Approach 2:
The patent employs composite material construction by assembling different materials with complementary properties into a unified heat exchanger module. The metal casing offers mechanical strength, the fusible metal inserts provide thermal pathways, and polymer components offer chemical resistance, creating a multi-material composite structure that optimizes overall performance while addressing the challenges of joining dissimilar materials through controlled manufacturing processes.
2Reliability
If complex geometries are manufactured to improve heat exchange efficiency, then the thermal performance is improved, but the manufacturing difficulty and cost increase
Solution Approach 1:
The patent segments the heat exchanger manufacturing into distinct modular steps: fabricating the metal casing, inserting fusible metal elements, adding polymer components, and performing selective melting. This segmentation allows complex geometries to be built up systematically through controlled material addition and transformation, making the manufacturing of thermally efficient complex shapes more manageable and cost-effective.
Solution Approach 2:
The patent utilizes parameter changes, specifically temperature-controlled selective melting of the fusible metal, to transform the structure and create complex internal geometries. By controlling the melting temperature and applying heat selectively, the process can form intricate heat exchange passages and optimize thermal pathways without requiring complex machining operations, thereby improving heat exchange efficiency while maintaining manufacturing feasibility.
3Ease of manufacture
If traditional manufacturing methods are used to maintain simple processes, then the manufacturing simplicity is preserved, but defects like porosity and mechanical stress remain
Solution Approach 1:
The patent replaces traditional mechanical joining and forming methods with a thermal field-based approach. Instead of mechanically assembling multiple components or using complex machining, the process uses controlled heating to selectively melt the fusible metal, which then flows and bonds with surrounding materials. This substitution of mechanical processes with thermal field control eliminates porosity and reduces mechanical stress while maintaining relative manufacturing simplicity.
Solution Approach 2:
The patent exploits phase transitions, specifically the melting and solidification of the fusible metal, to create defect-free joints and complex geometries. During the melting phase, the metal becomes fluid and can flow into gaps and bond with surrounding materials, eliminating porosity. Upon controlled solidification, the metal forms strong, stress-free joints. This phase transition mechanism achieves high manufacturing precision while keeping the process relatively simple compared to traditional mechanical methods.
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 simplifies the manufacturing process, enables more efficient filling of the heat exchanger module, and improves both thermal and mechanical properties by eliminating defects, while allowing for complex geometries and reduced deformations.
Implementation Method 1
heating of the sealed casing until the element(s) melt into at least one fusible metal or metal alloy
Implementation Method 2
Hot Isostatic Compression to eliminate defects and enhance properties
Data Source
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Figure 7~8A
AI summary
The invention relates to a method for making a heat exchanger module with at least one fluid circuit, which combines a structure having high thermal properties due to the presence of one or more materials having good thermal characteristics and the use of a material with good mechanical properties for the structural elements of the heat exchanger module.