Micro Tube Heat Exchanger Vibration Insertion Method
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Solution Overview
Problem
The manufacturing of micro tube heat exchangers is challenging due to the high cost and time required for drilling header and mid plates with precise hole patterns, and the unreliable joining of thousands to millions of micro tubes to the header plates, leading to potential leaks and increased production costs.
Innovation Solution
A method involving the alignment and vibration of micro tubes through aligned apertures in end and mid plates, followed by affixing them to form a leak-free seal, using a stack of lamina and adhering them together with a sealant to create a compact and efficient heat exchanger.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If drilling is used to manufacture header plates and mid plates with precise hole patterns, then manufacturing precision is improved, but manufacturing cost and time increase significantly
Solution Approach 1:
The patent applies preliminary action by pre-forming the header plates and mid plates with the precise hole patterns before tube insertion. The plates are manufactured with predetermined aperture locations and dimensions that match the tube bundle requirements, eliminating the need for time-consuming on-site drilling operations. This pre-preparation of precise components resolves the contradiction by achieving high manufacturing precision while reducing overall manufacturing time.
Solution Approach 2:
The patent replaces the mechanical drilling process with a pre-formed plate system. Instead of using drilling machinery to create holes in the header plates during assembly, the plates are supplied with pre-formed apertures through alternative manufacturing processes (such as punching, stamping, or additive manufacturing). This substitution eliminates the time-consuming drilling operation while maintaining the required precision of hole spacing and dimensions.
2Strength
If drilling is used for thick header plates, then structural strength is improved, but manufacturing time increases substantially
Solution Approach 1:
The patent applies preliminary action by pre-forming the thick header plates with the required aperture patterns before assembly. The plates are manufactured with precise holes already in place, eliminating the need for time-consuming drilling operations on thick materials during the assembly process. This resolves the contradiction by maintaining structural strength through proper plate design while dramatically reducing manufacturing time.
Solution Approach 2:
The patent employs mechanical vibration during the tube insertion process to facilitate passage through the pre-formed apertures in the thick header plates. By vibrating the tubes or the plates, the process enables easier insertion through the precisely formed holes without requiring time-consuming drilling operations, thus resolving the time-strength contradiction.
3Strength
If traditional joining processes are used to connect thousands of micro tubes to header plates, then structural integrity is improved, but reliability decreases due to potential leaks
Solution Approach 1:
The patent merges the structural support function and sealing function into a single integrated header plate design. The header plates are designed with apertures that provide both mechanical support for the tubes and sealing surfaces that prevent leakage. This integration eliminates the need for separate sealing components and complex multi-step joining processes, thereby improving reliability by reducing potential failure points while maintaining structural integrity.
Solution Approach 2:
The patent applies self-service by designing the header plates with self-sealing apertures that automatically provide both structural support and leak-free sealing. The aperture design and tube insertion process are configured so that the tubes themselves contribute to the sealing mechanism, eliminating the need for additional sealing operations. This self-sealing capability improves reliability by ensuring consistent leak-free connections across all thousands of tube-to-header joints.
4Reliability
If tight clearance is maintained for bonding/sealing process, then sealing reliability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies parameter changes by optimizing the aperture diameter and tolerance parameters to achieve the desired tight clearance for reliable bonding and sealing. The header plate apertures are manufactured with specific dimensional parameters that provide the optimal balance between tight clearance for sealing and achievable manufacturing precision. By carefully selecting and controlling these parameters, the patent achieves high seal reliability without requiring excessively tight tolerances that would be difficult and expensive to manufacture.
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 significantly reduces manufacturing costs and time, achieving a high success rate of leak-free seals, thereby enhancing the commercial viability of micro tube heat exchangers by facilitating quick and inexpensive insertion of micro tubes and reliable bonding.
Implementation Method 1
vibrating at least one of the micro tubes while the micro tubes are on the first end plate, thereby causing the micro tubes to insert into and through respective aligned apertures
Implementation Method 2
affixing each end portion of the micro tubes to a respective end plate, thereby forming a pathway in a micro tube heat exchanger component for the flow of an internal fluid
Data Source
AI summary
A method including disposing a first end plate adjacent to a second end plate, wherein the first end plate and second end plate each define a pattern of apertures. The first end plate is aligned with the second end plate such that the pattern of apertures in the first end plate is substantially aligned with the pattern of apertures in the second end plate. The method includes placing an end portion of each of a plurality of micro tubes in contact with the first end plate, the micro tubes being substantially vertically disposed and substantially perpendicular to a top surface of the first end plate, so as to place the micro tubes on the first end plate, and vibrating at least one of the micro tubes while the micro tubes are on the first end plate, thereby causing the micro tubes to insert into and through respective aligned apertures of the patterns of apertures in the first end plate and the second end plate. The method further includes separating the first end plate from the second end plate while the micro tubes extend therethrough, until the first end plate and the second end plate are disposed proximate to respective end portions of the micro tubes extending therethrough, and affixing each end portion of the micro tubes to a respective end plate, thereby forming a pathway in a micro tube heat exchanger component for the flow of an internal fluid to be heated or cooled by external flow of an external fluid.