Plate Laminate Heat Exchanger Welding Under Compression
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Solution Overview
Problem
Existing methods for producing a plate laminate unit for a heat exchanger do not provide a specific method for properly welding the pair of terminal plates to the edge portion of the plate laminate, which can lead to refrigerant leakage.
Innovation Solution
A method involving a compressing step to bring the edge portions of the plate laminate into close contact with the terminal plates, followed by welding along their entire circumferential length, using a pressing tool to ensure proper welding and connection, and a pressure-releasing step to maintain the compressed state without interfering with the welding process.
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 and refrigerant leakage occurs
Solution Approach 1:
The pressing tool is used to compress the terminal plates and plate laminate together before welding, bringing their edge portions into close contact. This preliminary compression action ensures proper welding conditions are established before the welding process begins, preventing refrigerant leakage while maintaining a relatively simple device structure.
2Reliability
If plate laminate is compressed before welding, then welding quality improves, but plate laminate deformation increases
Solution Approach 1:
Compression is applied as a preliminary action before welding to ensure proper contact between surfaces. The compression is maintained only during the welding process, allowing the plate laminate to be compressed into the correct shape temporarily for welding, then released afterward to prevent permanent deformation while ensuring high welding quality.
Solution Approach 2:
The pressing tool applies dynamic compression force during the welding process and then releases it afterward. This dynamic application of compression allows the plate laminate to be shaped correctly during welding without permanent deformation, resolving the contradiction between welding quality and shape maintenance.
3Productivity
If terminal plates are welded without compression, then manufacturing process is faster, but refrigerant leakage occurs
Solution Approach 1:
The pressing tool is designed to compress the terminal plates and plate laminate together before welding in a single integrated operation. This preliminary compression is built into the welding process itself, so that the compression and welding occur as one continuous action, maintaining high manufacturing speed while ensuring reliable leakage prevention through proper welding quality.
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
Enables proper welding of the terminal plates to the plate laminate, preventing refrigerant leakage and promoting effective heat exchange by maintaining the compressed state and suppressing tensile stress at the welds, even under high-pressure fluid conditions.
Implementation Method 1
compressing a plate laminate (40), a pair of terminal plates (110) disposed on both sides of the plate laminate (40) in a laminating direction, and a pair of binding plates (120) disposed on both sides of the pair of terminal plates (110) in the laminating direction, using a pressing tool (200) from both sides in the laminating direction
Implementation Method 2
welding an edge portion (49) of the plate laminate (40) to edge portions (119) of the pair of terminal plates (110)
Data Source
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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.