Method for manufacturing heat transfer element
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Solution Overview
Problem
Conventional heat exchange elements require costly die molding for varying sizes, increasing manufacturing costs and complexity.
Innovation Solution
A manufacturing method using alternately stacked corrugated partition and spacing plates, with tape joints, forming opposing and separator flow-path portions, allowing for a wide range of sizes without the need for a die-molded element frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an element frame with sealing rib and supporting frame is used to form the opposing flow-path portion, then the structural strength and sealing performance are improved, but the manufacturing cost increases due to the need for die molding for each size variation
Solution Approach 1:
The invention extracts and eliminates the element frame structure (sealing rib and supporting frame) from the heat exchange element. Instead of using a separate frame to provide structural support and sealing, the patent uses the partition plates themselves to form the opposing flow-path portion, thereby removing the need for die molding of frames while maintaining structural integrity through the stacked partition plate configuration
Solution Approach 2:
The partition plates serve multiple functions: they provide the heat exchange surface, form the flow paths, and replace the structural support function previously performed by the element frame. By making the partition plates multi-functional, the invention eliminates the need for separate framing structures and reduces manufacturing complexity for different sizes
2Reliability
If an element frame with sealing rib and supporting frame is used to form the opposing flow-path portion, then the structural integrity is improved, but the device complexity increases due to additional components
Solution Approach 1:
The invention merges the functions of the element frame, partition plates, and flow path formation into a single integrated structure. The partition plates are stacked alternately with spacing to directly form the opposing flow-path portion, combining what were previously separate components (frame and internal structure) into one unified assembly, thereby reducing device complexity
Solution Approach 2:
The element frame structure is extracted and removed from the design. The patent relies solely on the stacked partition plates to provide structural integrity and define flow paths, eliminating the sealing rib and supporting frame components and thereby reducing the total number of parts
3Manufacturing precision
If die molding is used to manufacture the element frame in accordance with the size of the opposing flow-path portion, then the manufacturing precision is improved, but the productivity decreases due to the need for custom dies for each size
Solution Approach 1:
The heat exchange element is segmented into standardized partition plates that can be manufactured using common molding processes. These modular partition plates are then stacked in different quantities and configurations to create heat exchange elements of various sizes, eliminating the need for custom die molding for each size while maintaining manufacturing precision through standardized components
Solution Approach 2:
Instead of changing the die mold to accommodate different sizes, the invention changes the number of stacked partition plates and their arrangement configuration. This parameter change approach allows flexible size variation without requiring new tooling, thereby improving productivity while maintaining dimensional accuracy through standardized plate dimensions
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
Reduces manufacturing costs and accommodates various sizes by eliminating the need for die-molded frames and supporting structures, while maintaining efficient air flow and heat exchange.
Implementation Method 1
heat exchange is performed through the partition plate between air flows that pass along adjacent flow paths with the partition plate interposed therebetween
Implementation Method 2
causing a supplied-air flow to pass along a flow path formed on one side of the partition plate and an exhaust-air flow to pass along a flow path formed on the other side, thereby exchanging heat between the supplied-air flow and the exhaust-air flow
Implementation Method 3
Each of the partition plates of the opposing flow-path portion and each of the partition plates of the first flow-path separator portion are joined with a tape
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A heat exchange element (1) includes an opposing flow-path portion (13); a first flow-path separator portion (14); and a second flow-path separator portion (15), each of which is formed by alternately stacking a plurality of partition plates (2) and a plurality of spacing plates (3) having a corrugated shape in cross section. In the opposing flow-path portion (13), the spacing plates (3) are disposed in such a manner that peaks of the corrugated shape extend parallel to each other when viewed in a direction in which the partition plates (2) and the spacing plates (3) are stacked, and a first flow path and a second flow path are formed alternately with the partition plate (2) interposed between the first and second flow paths. The first flow-path separator portion (14) and the second flow-path separator portion (15) separate air that flows through the first flow path and air that flows through the second flow path from each other in different directions. Each partition plate (2) of the opposing flow-path portion (13) and each partition plate (2) of the first flow-path separator portion (14) are joined with a tape (7). Each partition plate (2) of the opposing flow-path portion (13) and each partition plate (2) of the second flow-path separator portion (15) are joined with the tape (7).