Refrigerant Flow Path Module Brazing with Fastening to Prevent Warpage
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Solution Overview
Problem
Existing methods for manufacturing refrigerant flow path modules face challenges in accurately joining stacked metal plates due to warpage, which can result in inadequate brazing material penetration and potential moisture infiltration, leading to damage from freezing expansion.
Innovation Solution
A method involving the use of a fastening member with a lower thermal expansion coefficient than the plates, which corrects warpage and ensures appropriate brazing material penetration, combined with filling gaps with brazing material and providing openings to prevent moisture accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal plates are stacked and brazed by heating in a furnace, then the plates are joined together, but warpage occurs causing inadequate brazing material penetration
Solution Approach 1:
The patent applies preliminary action by fastening the metal plates together before brazing. Fastening members are inserted through insertion holes in the stacked plates and secured with nuts, establishing a fixed, flat configuration before the brazing process begins. This preliminary mechanical fastening prevents warpage during subsequent heating, ensuring proper brazing material penetration and reliable joints.
2Reliability
If gaps between plates are not filled, then manufacturing is simpler, but moisture infiltration causes freezing expansion damage
Solution Approach 1:
The patent uses brazing material as an intermediary substance that serves dual functions. The brazing material is applied to the stacking surfaces of the metal plates and, when melted during brazing, fills gaps between the plates while creating a strong metallurgical bond. This intermediary material simultaneously achieves moisture sealing to prevent freezing damage and provides structural joining, eliminating the need for separate sealing components.
3Manufacturing precision
If fastening members are used to correct warpage, then brazing quality improves, but thermal expansion differences may cause stress
Solution Approach 1:
The patent addresses thermal stress by changing the material parameter of the fastening members. Instead of using the same metal material as the plates, the fastening members are made from materials with thermal expansion coefficients matched to the plate material. This parameter change ensures that during heating and cooling cycles, the fastening members and plates expand and contract together, preventing differential thermal stress and maintaining joint integrity.
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 effectively joins plates with reduced gaps, ensuring reliable brazing and preventing moisture-induced damage, thereby enhancing the durability and performance of refrigerant flow path modules.
Implementation Method 1
a brazing material is attached to a stacking surface of a plurality of metal plates to be stacked and brazed by heating in a furnace
Implementation Method 2
heating the first plate and the second plate fastened by the fastening member in a furnace
Implementation Method 3
fastening the first plate and the second plate between which the brazing material is disposed with a fastening member
Data Source
AI summary
A method for manufacturing a refrigerant flow path module including a first plate and a second plate stacked on each other and including a refrigerant flow path inside includes arranging a brazing material between the first plate and the second plate, fastening the first plate and the second plate between which the brazing material is disposed with a fastening member, and heating the first plate and the second plate fastened by the fastening member in a furnace.