Multilayer Heat Exchanger Panel Assembly for Precise Sheet Alignment
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Solution Overview
Problem
There is an ongoing need for improvements in the design and manufacturability of panels used in three-way heat exchangers to reduce costs and optimize operation and efficiency in HVAC systems that utilize liquid desiccants and heat transfer fluids for heating, ventilation, and air conditioning.
Innovation Solution
A method of assembling multilayer panels for heat exchangers involves positioning a frame on a work platform, attaching heat exchange sheets with alignment pins, and welding them to the frame to ensure precise alignment and sealing, while incorporating membranes to separate desiccant and heat transfer fluid channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional panel assembly methods are used for three-way heat exchangers, then manufacturing complexity is reduced, but manufacturing precision and alignment accuracy deteriorate
Solution Approach 1:
The patent introduces alignment pins as intermediary components that mediate between the frame and heat exchange sheets. These pins physically bridge the two components, ensuring precise alignment during assembly while maintaining a relatively simple overall assembly process. The alignment pins act as a mediator that translates the requirement for high precision into a simple mechanical feature.
Solution Approach 2:
The alignment features are pre-formed on the frame and heat exchange sheets before the final welding assembly step. This preliminary action of creating alignment features in advance allows for quick and accurate positioning during assembly, improving manufacturing precision without adding complexity to the main assembly process.
2Manufacturing precision
If traditional welding methods are used without alignment features, then assembly process is simpler, but welding precision and sealing quality deteriorate
Solution Approach 1:
The alignment pins serve as intermediaries that facilitate precise welding by holding the frame and heat exchange sheets in the correct relative positions during the welding process. This intermediary mechanism enables high welding precision while keeping the assembly process straightforward, as the pins simply need to be inserted and removed after welding.
Solution Approach 2:
The patent replaces complex mechanical alignment systems with simple pin-based alignment features. Instead of using elaborate mechanical fixtures or complex positioning mechanisms, the invention uses basic pin insertion to achieve precise alignment, thereby improving welding precision while maintaining ease of manufacture.
3Productivity
If panel design is optimized for heat and moisture transfer, then heat exchanger efficiency improves, but manufacturing cost and complexity increase
Solution Approach 1:
The heat exchange sheets are designed as separate, modular components that can be manufactured independently and then assembled with the frame using alignment pins. This segmentation allows for optimization of heat and moisture transfer performance in the sheets while keeping the manufacturing process simple and cost-effective through standardized assembly procedures.
Solution Approach 2:
The patent optimizes parameters such as sheet thickness, material composition, and channel geometry to improve heat and moisture transfer efficiency. These parameter changes are implemented in a way that maintains compatibility with simple alignment and welding processes, thereby improving productivity without significantly increasing manufacturing complexity.
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 enhances the efficiency and cost-effectiveness of HVAC systems by improving the design and manufacturability of panels, facilitating better heat and moisture transfer in three-way heat exchangers.
Implementation Method 1
inserting an alignment pin of the work platform into each pair of corresponding frame and sheet alignment features
Implementation Method 2
welding the heat exchange sheet to the frame
Implementation Method 3
incorporating membranes to separate desiccant and heat transfer fluid channels
Implementation Method 4
heat exchange sheet...facilitating better heat and moisture transfer in three-way heat exchangers
Data Source
AI summary
Methods of assembling a multilayer panel for use in a heat exchanger. An example method includes positioning a frame on a work platform, the frame having two header sections and a middle section, the middle section defining a heat transfer fluid area and each header section defining a frame alignment feature; positioning a heat exchange sheet on the frame across the middle section and each header section, the heat exchange sheet having two sheet alignment features each corresponding to one of the frame alignment features; inserting an alignment pin of the work platform into each pair of corresponding frame and sheet alignment features; and welding the heat exchange sheet to the frame.