Plate Laminate Heat Exchanger Assembly for Leak-Free Edge Welding
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Solution Overview
Problem
Existing methods for producing plate laminate units for heat exchangers do not provide a specific method for properly welding the edge portions of terminal plates to the plate laminate, which can lead to leakage of refrigerants.
Innovation Solution
A method involving a compressing step using a pressing tool to bring the edge portions of the plate laminate and terminal plates into close contact, followed by a welding step to securely weld these edges, and subsequent connecting and pressure-releasing steps to assemble the plate laminate unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If terminal plates are welded to plate laminate without proper compression, then welding process is simpler, but welding quality deteriorates leading to refrigerant leakage
Solution Approach 1:
The patent applies preliminary compression to the terminal plates and plate laminate before welding to ensure proper contact and alignment. The pressing tool is used in advance of the welding step to compress the components, creating optimal conditions for high-quality welding without requiring complex adjustments during the welding process itself.
2Strength
If pressing tool is removed before connector installation, then assembly is easier, but tensile stress at weld points increases
Solution Approach 1:
The connector is installed while the pressing tool is still in place, maintaining compression on the assembly. This preliminary action ensures that the weld joints are under compressive stress during connector installation, preventing tensile stress from developing at the weld points. Only after the connector is securely in place is the pressing tool removed.
3Reliability
If terminal plates are welded without compression, then manufacturing is simpler, but refrigerant leakage occurs
Solution Approach 1:
The patent merges the compression and welding operations into a coordinated sequence where the pressing tool remains in place throughout the welding process. This combination ensures continuous compression during welding, guaranteeing leak-free joints while maintaining production efficiency through a streamlined, integrated process rather than separate, repeated operations.
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 ensures proper welding of the terminal plates to the plate laminate, preventing refrigerant leakage and allowing for efficient heat exchange, while also suppressing tensile stress at the weld points.
Implementation Method 1
a compressing step of compressing a plate laminate, a pair of terminal plates disposed on both sides of the plate laminate in a laminating direction
Implementation Method 2
a welding step of welding an edge portion of the plate laminate to edge portions of the pair of terminal plates during the compressing step
Data Source
AI summary
A method of producing a plate laminate unit for a heat exchanger includes: a compressing step of compressing a plate laminate, a pair of terminal plates disposed on both sides of the plate laminate in a laminating direction, and a pair of binding plates disposed on both sides of the pair of terminal plates in the laminating direction, using a pressing tool from both sides in the laminating direction; a welding step of welding an edge portion of the plate laminate to edge portions of the pair of terminal plates during the compressing step; a connecting step of connecting the pair of binding plates to each other by a connector after the welding step; and a pressure-releasing step of detaching the pressing tool after the connecting step.