Plate Heat Exchanger Assembly With Seam-Formed Spacer Edges
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Solution Overview
Problem
The production of plate heat exchangers is characterized by a high energy requirement due to the large number of components that need to be welded together, which is inefficient in terms of resource consumption and energy usage.
Innovation Solution
The method involves forming plate pairs by bending metal sheets to create standing seams, which then replace the need for separate spacers, thereby reducing the number of weld seams and energy expenditure. Additionally, elongate spacers with L-shaped, C-shaped, or complex cross-sections are used to further enhance mechanical stability and reduce the need for additional spacers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a large number of separate spacers and components are used to form the plate stack, then the mechanical stability and structural integrity are improved, but the number of weld seams increases leading to high energy consumption and resource usage
Solution Approach 1:
The patent combines the functions of separate spacers and plate components into an integrated plate structure with built-in sealing edges and positioning features. The plate includes integrated elements that previously required separate spacer components, reducing the total number of parts and weld seams while maintaining mechanical stability and structural integrity
Solution Approach 2:
The plate design incorporates multiple functions into single components. The plate serves both as a heat transfer surface and as a structural element with integrated sealing and positioning functions. The sealing edge and positioning features are built into the plate itself, making it a multi-functional component that replaces several separate parts
2Manufacturing precision
If many individual components are welded together to form the plate heat exchanger, then the assembly precision and structural integrity are improved, but the manufacturing complexity and production time increase
Solution Approach 1:
The plate is designed as a modular component with integrated features that simplify assembly. The plate stack is formed by stacking these standardized plates with integrated sealing edges, reducing the complexity of assembly compared to joining multiple separate components. The segmentation is optimized to balance manufacturing simplicity with assembly precision
3Reliability
If a large number of components are used in the plate stack assembly, then the functional performance is improved, but the resource consumption and waste generation increase
Solution Approach 1:
The patent merges multiple functions into fewer components, reducing the total material usage. The integrated plate design eliminates the need for separate spacer components and reduces the number of sealing elements required, thereby decreasing resource consumption and waste generation while maintaining functional performance
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 significantly reduces the number of weld seams and process complexity, leading to a substantial decrease in energy consumption and resource usage while maintaining or improving the mechanical stability of the plate heat exchanger.
Implementation Method 1
bending the metal sheets along a marginal edge running in the longitudinal direction, whereby a seam, in particular a standing seam, running in the longitudinal direction is formed per metal sheet
Implementation Method 2
the two individual plates being welded together along their respective seams and the free marginal edges cooperating therewith
Data Source
AI summary
A method of manufacturing a plate heat exchanger comprises bending metal sheets along a marginal edge running in the longitudinal direction to define a seam per metal sheet, forming a plate pair by arranging two plates on top of the other in a stacking direction and welding them together. The two plates are turned towards each other with their respective seams such that a seam of one plate is assigned to a free marginal edge of the other plate and the two plates being welded together along their respective seams. The method includes forming a plate stack by arranging and welding at least two plate pairs on top of the other. A first spacer extends along a first longitudinal edge and a second spacer extends along a second longitudinal edge with the spacers being welded together, the elongate spacers having an L-shaped cross-section, a C-shaped cross-section and/or a complete cross-section.