Method for producing a plate heat exchanger with multiple heat exchanger blocks connected by solder-coated supports
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Solution Overview
Problem
Existing plate heat exchangers with multiple blocks face high stress concentrations and poor thermal contact at the transition regions, limiting their mechanical strength and operational reliability due to limited connection methods that do not effectively distribute heat or stress across the blocks.
Innovation Solution
A method involving the use of a soldered metal support to connect the outer surfaces of heat exchanger blocks, forming a full-area or partial-area connection that enhances mechanical strength and thermal conductivity, reducing stress concentrations and improving temperature equalization between blocks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If heat exchanger blocks are connected by welding bars at the periphery only, then the blocks can be joined together, but high stress concentrations occur in the transitional region and thermal contact is poor
Solution Approach 1:
A solder-coated support acts as an intermediary element between the heat exchanger blocks. The support is coated with solder that melts at a specific temperature, creating a frictional connection when pressed against the blocks. This intermediary distributes stress across a larger area compared to peripheral welding alone, reducing stress concentrations at the transition regions while maintaining mechanical strength.
Solution Approach 2:
The invention combines welding and frictional connection methods into a hybrid joining system. Welding bars provide structural framework at the periphery, while the solder-coated support creates distributed frictional contact across the connection interface. This merging of connection methods achieves both strong mechanical bonding and reduced stress concentration.
2Ease of manufacture
If heat exchanger blocks are connected with limited contact area, then assembly is simple, but thermal contact between blocks is poor leading to temperature differences
Solution Approach 1:
The solder coating on the support changes its physical state from solid to liquid at a specific melting temperature, enabling the support to conform to the block surfaces and maximize contact area. This parameter change (phase transition) transforms a simple assembly process into an effective thermal contact solution, as the molten solder fills gaps and creates intimate thermal contact when cooled.
Solution Approach 2:
The solder-coated support serves as a thermal intermediary that improves heat transfer between blocks. The solder material, with its high thermal conductivity and ability to flow into surface irregularities, creates a superior thermal bridge compared to direct metal-to-metal contact, enabling better temperature equalization while maintaining assembly simplicity.
3Area of stationary object
If larger heat exchanger blocks are produced, then the heat-exchanging surface area increases, but the block size exceeds the capacity of conventional brazing furnaces
Solution Approach 1:
The heat exchanger is segmented into multiple separate blocks that are each within the capacity of conventional brazing furnaces. These blocks are then joined together using the welding bar framework and solder-coated support system. This segmentation allows the total heat-exchanging surface area to exceed furnace limitations while maintaining manufacturability of individual components.
Solution Approach 2:
Multiple heat exchanger blocks are nested or stacked together to form a composite structure that achieves the required total surface area. The solder-coated support enables this nesting by creating a stable frictional connection between stacked blocks, allowing the system to achieve large overall dimensions through composition of smaller, furnace-compatible units.
4Strength
If solder-coated support is heated to melt the solder for connection, then a frictional and material-bonded connection is achieved, but additional heating equipment and process steps are required
Solution Approach 1:
The solder coating undergoes a phase transition from solid to liquid when heated to its melting temperature, enabling the support to conform to block surfaces and create maximum contact area. Upon cooling, the solder solidifies again, forming a strong material-bonded connection. This phase transition mechanism achieves enhanced connection strength through a controlled thermal process that, while adding equipment, provides superior bonding compared to mechanical fastening alone.
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 significantly increases the mechanical strength and operational reliability of the plate heat exchanger by creating a stable, frictional connection and improved thermal contact between blocks, allowing for larger and more complex heat exchanger configurations with reduced thermal stresses.
Implementation Method 1
at least one support provided with solder is heated to melt the solder
Implementation Method 2
the heat exchanger blocks to be connected are placed one on top of the other or one against the other in such a way that the at least one support is secured between opposing outer surfaces
Implementation Method 3
the outer surfaces of the heat exchanger blocks are connected to one another in a heat-conducting manner by the at least one support attached by solder
Data Source
AI summary
A method for producing a plate heat exchanger with at least two heat exchanger blocks which are produced separately from one another in a soldering furnace Each heat exchanger block has multiple separating sheets arranged parallel to one another and which form a plurality of beat exchanger passages for fluids involved in a heat exchange process. At least one support provided with solder is heated in order to melt the solder, the support is arranged between opposing outer surfaces of the heat exchanger blocks to be connected which are placed one on top of the other or adjacently, the support(s) thus being fixed between the opposing outer surfaces. After the solder is hardened, a bonded and heat-conductive connection is produced between the heat exchanger blocks. Sheets or wire arrangement can be used as the supports.