Modular Heat Exchanger Assembly via Segmented Diffusion Welding
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Solution Overview
Problem
The existing methods for manufacturing heat exchangers with large dimensions and/or a large number of channels face challenges such as excessive deformation, high manufacturing costs, and difficulties in achieving optimal sealing and mechanical strength, particularly due to limitations in the uniaxial diffusion-welding process and Hot Isostatic Compression (CIC) techniques.
Innovation Solution
The method involves producing elementary exchanger modules by diffusion welding of grooved plates, followed by reducing the width of edges and thickness of anvils, and edge-to-edge positioning of these modules for assembly, allowing for a one-piece exchanger with minimal deformation and enhanced compactness, using a low-pressure CIC cycle to finalize the assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If uniaxial diffusion welding or Hot Isostatic Compression (CIC) is used to assemble plates with channels, then mechanical strength and sealing are improved, but channel deformation increases excessively for large dimensions and/or large number of channels
Solution Approach 1:
The heat exchanger is divided into multiple elementary modules, each containing a limited number of stacked plates (e.g., 5-15 plates per module). These modules are assembled separately using diffusion welding or CIC, minimizing deformation within each module. The modules are then connected externally to form the complete heat exchanger with a large number of channels, thus avoiding excessive deformation that would occur if all plates were assembled in a single large stack.
Solution Approach 2:
Instead of assembling all plates in a single vertical stack along one dimension, the invention transitions to a modular architecture where plates are first assembled in smaller stacks within elementary modules, and then these modules are connected in a second dimension (horizontally or laterally). This dimensional transition distributes the welding forces and reduces the cumulative deformation effect on individual channels.
2Quantity of substance
If the number of channels and dimensions of the heat exchanger are increased, then heat exchange capacity is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The manufacturing process is segmented into two distinct stages: (1) production of elementary modules with limited plates and channels using diffusion welding or CIC, and (2) external assembly of these modules to achieve the desired total number of channels. This segmentation allows standardization of module production, reducing manufacturing complexity and cost compared to producing a single large-scale heat exchanger with all channels assembled simultaneously.
Solution Approach 2:
Elementary modules are produced in advance as standardized components with pre-assembled plates and channels. These pre-fabricated modules can be manufactured, inspected, and stored independently before final assembly into the complete heat exchanger. This preliminary action simplifies the overall manufacturing process, enables quality control at the module level, and reduces the complexity of assembling a large number of channels in a single operation.
3Reliability
If diffusion welding is used to assemble plates, then sealing efficiency is improved, but additional manufacturing costs increase
Solution Approach 1:
Diffusion welding is applied only to assemble the plates within each elementary module, rather than welding all plates in a single large stack. This segmentation reduces the total number of welding operations required, as modules can be assembled separately with fewer interfaces. The reduced welding workload lowers manufacturing costs while maintaining high sealing efficiency within each module. Modules are then connected using alternative joining methods or external sealing mechanisms.
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 enables the production of heat exchangers with numerous channels and large dimensions while maintaining compactness and minimizing additional costs, by distributing the welding force evenly and reducing material stress, thus improving the mechanical strength and sealing efficiency.
Implementation Method 1
assembly by diffusion welding between the element(s) of the first circuit and the element(s) of the second circuit, stacked one on top of the other
Implementation Method 2
assembly by diffusion welding between the element(s) of the first circuit and the element(s) of the second circuit, stacked one on top of the other
Data Source
Figure 1~2B
Figure 3A~3C
Figure 4~6
AI summary
The invention relates to a method for manufacturing heat exchangers (1) with at least two fluid circuits, each comprising channels made from grooved plates. In this method according to the invention, elementary exchanger modules (1.1, 1.2, 1.3...) are assembled, each of which has been previously produced by diffusion welding of grooved plates.