Plate Heat Exchanger Alignment Patterns for Versatile Assembly
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Solution Overview
Problem
Existing plate heat exchangers with multiple fluid circuits face high manufacturing costs and limited versatility due to the labor-intensive and expensive techniques used for engraving grooves, which restricts the modification of channel geometry and alignment of plates during assembly.
Innovation Solution
A method involving the formation of alignment patterns on plates, allowing for the superposition and diffusion-welding or brazing of plates with grooves for fluid channels, enabling the production of heat exchangers with varying configurations using the same set of plates, reducing costs and enhancing versatility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional machining or chemical etching is used to engrave grooves on plates, then channel geometry can be created, but manufacturing costs increase and versatility is limited
Solution Approach 1:
The plate surface is segmented into multiple grooves that are arranged in specific patterns. These grooves are created as separate features that can be independently positioned and configured, allowing for flexible channel geometry design without requiring complex machining operations for each unique configuration.
Solution Approach 2:
A single plate design with standardized groove patterns can serve multiple functions and configurations. The same plate can be used in different heat exchanger arrangements to create various channel geometries by changing the assembly configuration rather than manufacturing new plates for each geometry.
2Manufacturing precision
If plates are assembled with precise alignment requirements, then channel geometry can be controlled, but assembly complexity and time increase
Solution Approach 1:
Alignment patterns are pre-formed on the plates during the plate manufacturing process, before assembly. These patterns serve as built-in alignment guides that automatically ensure correct positioning when plates are stacked, eliminating the need for time-consuming alignment operations during assembly.
Solution Approach 2:
The alignment patterns on the plates enable the assembly process to self-align the plates correctly through simple stacking. The patterns act as self-aligning features that guide the plates into proper position without requiring external alignment tools or complex adjustment procedures.
3Strength
If diffusion welding or brazing is used to join plates, then mechanical strength is improved, but manufacturing complexity increases
Solution Approach 1:
The alignment patterns and groove features are integrated into a single plate manufacturing process. This merging of features reduces the number of separate manufacturing steps and tooling requirements, simplifying the overall process while maintaining the mechanical strength benefits of diffusion welding or brazing.
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 allows for more versatile designs of heat exchangers by enabling the production of different fluid circuit configurations using the same set of plates, improving the efficiency and compactness of heat exchangers.
Implementation Method 1
The assembly of the plates together aims to ensure the sealing and/or mechanical strength of the exchangers... Assembly can also be achieved by diffusion welding... Diffusion welding involves creating a solid joint by applying a hot force to the parts to be joined for a specific time. The applied force serves a dual purpose: it enables contact, i.e., bringing the surfaces to be welded into contact, and it facilitates the elimination of residual porosity in the joints (interfaces) through creep-diffusion.
Implementation Method 2
Assembly can also be achieved by brazing, particularly for heat exchangers with added fins.
Data Source
Figure 1~1B
Figure 1C~4B
Figure 5~6B
AI summary
The main object of the invention is a method for manufacturing at least one plate heat exchanger (50) (10) with at least two fluid circuits, characterized in that it comprises the following steps: a) forming a plurality of plates (10), each having a reference pattern; b) forming one or more alignment patterns (11) on each plate (10) by circular repetition of the reference pattern around an axis of revolution (X); c) forming a plurality of grooves (12) on each plate (10). The method further comprises the following successive steps: d) assembling the plates (10) by superimposing them one on top of the other, each reference pattern of a plate being superimposed on an alignment pattern (11) of an adjacent plate; e) performing a joint treatment on the assembly obtained at the end of the preceding step d) by diffusion welding, brazing, and/or diffusion brazing.