Roll-Bond Heat Exchanger Plate With Integrated Degassing Port
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Solution Overview
Problem
Conventional roll-bond heat exchanger manufacturing processes are costly due to the need for additional processing steps and manpower, such as enlarging openings and welding aluminum tubes, which increases material and labor expenses.
Innovation Solution
An in-process roll-bond plate with a bulged structure and integrally formed degassing portion allows direct connection to a vacuum filling machine, reducing the need for additional processing steps and enabling cost-effective manufacturing by eliminating the need for adapting tubes and enlarged openings, while a U-shaped insertion portion ensures stable base insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional processes are used to manufacture roll-bond heat exchanger, then the heat exchanger can be manufactured, but additional processing steps (enlarging opening, welding aluminum tube, pressing) are required which increases manufacturing cost and processing complexity
Solution Approach 1:
The degassing portion is integrally formed with the roll-bond plate as a single part, merging two separate components (plate and degassing structure) into one. This eliminates the need for separate aluminum tubes and welding operations, directly reducing manufacturing cost and processing steps while maintaining the degassing function.
Solution Approach 2:
The degassing portion is pre-formed as an integral part of the roll-bond plate during the plate manufacturing process itself, before the heat exchanger assembly and refrigerant filling stages. This preliminary formation of the degassing structure eliminates the need for subsequent welding and opening enlargement operations.
2Ease of manufacture
If aluminum tube is welded to duct opening, then connection is achieved, but material cost (aluminum tube) and processing time (welding operation) increase
Solution Approach 1:
The degassing portion is integrated directly into the roll-bond plate structure, eliminating the need for separate aluminum tube components. This merging of components removes both the material cost of the tube and the time required for welding operations while maintaining the functional connection for degassing.
Solution Approach 2:
The separate aluminum tube component and welding operation are completely extracted from the manufacturing process. The degassing function is achieved through the integrally formed structure alone, removing unnecessary intermediate components and operations.
3Ease of operation
If opening of duct is enlarged to insert aluminum tube, then tube insertion is enabled, but additional processing steps and manpower are required
Solution Approach 1:
The degassing portion is formed as an integral extension of the roll-bond plate, merging the duct and degassing structure into one continuous component. This eliminates the need for opening enlargement operations and separate tube insertion steps, as the connection is built-in.
Solution Approach 2:
The degassing portion structure is preliminarily formed during plate manufacturing with the appropriate opening size and shape already configured. This preliminary preparation eliminates the need for subsequent opening enlargement and tube insertion 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
The integrated design reduces manufacturing costs and processing steps, enhances sealing efficiency, and allows for stable insertion on heat dissipating devices, improving overall manufacturing efficiency and reducing material waste.
Implementation Method 1
connecting the tube of the degassing portion to a connecting tube of a vacuum filling machine to remove air from the bulged structure
Implementation Method 2
pressing the bulged structure flat to form a pressed portion by using a pressing device
Implementation Method 3
welding the cut portion by using a welding device
Data Source
AI summary
A method for manufacturing a roll-bond heat exchanger has steps of: (1) A preparing step: preparing an in-process roll-bond plate that has a main plate with a bulged structure, and a degassing portion with a tube; (2) A degassing step: removing air from the bulged structure through the tube; (3) A filling step: filling refrigerant into the bulged structure; (4) A pressing step: pressing the bulged structure flat to form a pressed portion; (5) A cutting step: cutting the degassing portion to form a cut portion on the main plate; and (6) A sealing step: welding the cut portion. The main plate and the degassing portion are integrally formed as a single part and the degassing portion is able to be directly connected with the vacuum filling machine. Accordingly, processing steps and manpower for manufacturing the roll-bond heat exchanger are reduced.