Thermoplastic Frame Stack Fusion Bonding via Pressurized Melt
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Solution Overview
Problem
Existing processes for stacking thermoplastic frames, such as those used in plate heat exchangers, face challenges with the strength of the resulting stack when using snap-fit connections, and ultrasonic melting is laborious for connecting multiple frames.
Innovation Solution
A process involving stacking thermoplastic frames to form longitudinal and branched conduits, followed by supplying a pressurised melt of plastic material through these conduits while the stack is held together externally, resulting in fusion bonding between frames and creating a strong, water-tight connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If snap-fit connections are used to stack frames, then the stacking process is simple, but the strength of the resulting stack is insufficient
Solution Approach 1:
The patent changes the physical state of the plastic material from solid to molten by applying heat and pressure, then allows it to solidify and form a strong bond. This parameter change enables the material to transition from a simple mechanical connection state to a strong chemical bonding state, resolving the contradiction between ease of manufacture and connection strength.
Solution Approach 2:
The patent introduces a molten plastic material as an intermediary substance that fills the gap between frame surfaces and bonds them together. This intermediary material acts as a adhesive that creates strong, water-tight connections while allowing for relatively simple stacking and bonding operations.
2Strength
If ultrasonic melting is used to connect multiple frames, then strong connections are achieved, but the process becomes laborious
Solution Approach 1:
The patent merges multiple individual frame connection operations into a single simultaneous process. By supplying molten plastic material to multiple conduits at once, the patent connects multiple frames in one operation rather than connecting them sequentially, thereby reducing the total time required while maintaining strong connections.
Solution Approach 2:
The patent maintains continuous supply of molten plastic material through multiple conduits simultaneously, ensuring that the bonding process is continuous and efficient. This continuous action allows multiple frames to be connected in a single uninterrupted operation, reducing the time loss associated with repeated heating and bonding cycles.
3Ease of manufacture
If snap-fit connections are used, then the stacking process is simple, but the connections are not water-tight
Solution Approach 1:
The patent changes the physical state of the plastic material to molten, allowing it to flow into and fill the gaps between frame surfaces. When the material solidifies, it creates a water-tight seal that prevents leakage, while the process remains relatively simple compared to traditional welding methods.
Solution Approach 2:
The patent uses molten plastic material as an intermediary bonding agent that fills gaps and creates water-tight seals between frames. This intermediary material provides both the simplicity of the bonding process and the reliability of water-tight connections, resolving the contradiction between ease of manufacture and connection reliability.
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 process achieves a stack of firmly connected frames with fusion bonding that is stronger than snap-fit connections and water-tight, allowing for efficient and simultaneous connection of multiple frames, reducing labor and improving the structural integrity of the stack.
Implementation Method 1
As a result of stacking the frames and as a result of a elongated gutter as present on or in at least one side of the frame at the contact area a branched conduit is formed at the contact area, which branched conduit is fluidly connected to the longitudinal conduit, and wherein a pressurised melt of a plastic material is supplied to the elongated conduit and branched conduits while the stack is held together by external means to obtain the interconnected stack of thermoplastic frames. At the contact area fusion bonding between the material of neighbouring frames occurs.
Implementation Method 2
The plastic melt thereby mixes with the fusion surfaces of the frames resulting in a strong bond.
Data Source
Figure 1~2
Figure 3a~3d
AI summary
The invention is directed to a process to manufacture an interconnected stack of thermoplastic frames having two sides by stacking the thermoplastic frames to obtain a stack of frames such that the facing sides of two neighbouring frames are in contact with each other at a contact area. When stacking a longitudinal conduit is formed which runs along the length of the stack and a branched conduit is formed at the contact area. The interconnected stack of thermoplastic frames are obtained by supplying a pressurised melt of a plastic material to the elongated conduit and branched conduits.