Woven Microchannel Heat Exchanger Assembly Without Manual Tube Insertion

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Solution Overview

Problem

The manual insertion of tubular microchannels into glue frames or intermediate plates during the production of heat exchangers is time-consuming and prone to errors, affecting the stability and efficiency of the heat exchanger.

Innovation Solution

A method for producing a woven heat exchanger involves providing microchannel tubes for insertion into a weaving apparatus, weaving them within a central region, merging them into end regions to form circular cross-sections, gluing them, and shortening them to create a stable and efficient heat exchanger.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual insertion of tubular microchannels into glue frames is used, then flexibility and adaptability are maintained, but productivity is low and manufacturing precision is poor

Engineering Contradiction:

Improveproduction speedVSAvoidmanual insertion complexity

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent replaces the manual mechanical insertion process with an automated weaving machine that interweaves microchannel tubes with carrier wires in a single integrated operation. This mechanical substitution eliminates the need for separate manual insertion steps into glue frames, significantly improving productivity while maintaining manufacturing precision through consistent automated placement.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent merges the microchannel tube insertion process with the weaving process itself. The microchannel tubes are integrated into the woven structure during the weaving operation, combining what were previously separate steps (weaving and insertion) into a single unified process, thereby eliminating the need for separate glue frame assembly operations.

Inventive Principle:

Principle #5Merging (Combining)

2Manufacturing precision

If manual insertion of tubular microchannels is used, then adaptability to design changes is maintained, but manufacturing precision and consistency deteriorate

Engineering Contradiction:

Improveinsertion precisionVSAvoidproduction process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces manual insertion operations with an automated weaving mechanism that precisely positions microchannel tubes through programmed wire interweaving. This substitution ensures consistent manufacturing precision by eliminating human error and variability, while the automated system maintains adaptability through programmable control for different designs.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The weaving machine serves multiple functions: it weaves the carrier wires, positions the microchannel tubes, and integrates them into the final structure all in one operation. This multi-functionality reduces the need for multiple specialized devices and processes, simplifying the overall production system while maintaining high precision through automated control.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Loss of time

If manual insertion and assembly operations are used, then flexibility in production is maintained, but time consumption and cost increase

Engineering Contradiction:

Improveproduction timeVSAvoidoutput per unit time

Core Design Contradiction:

Loss of timeVSProductivity

Solution Approach 1:

The patent combines multiple sequential operations (weaving carrier wires, inserting microchannel tubes, assembling glue frames) into a single integrated weaving process. The microchannel tubes are incorporated during the weaving operation itself, eliminating the need for separate insertion and assembly steps, thereby dramatically reducing production time and increasing output per unit time.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces slow manual insertion and assembly operations with an automated weaving machine that operates continuously at high speed. This mechanical substitution transforms a labor-intensive, time-consuming process into an efficient automated production system, directly addressing the time loss and productivity issues associated with manual methods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS12281854B2Method for producing a woven heat exchanger

Publication Date: 2025.04.22 DR ING H C F PORSCHE AG

AI summary

A method for producing a woven heat exchanger, includes providing a plurality of microchannel tubes for insertion into a weaving apparatus and weaving the plurality of microchannel tubes within a central region of the heat exchanger by the weaving apparatus. The method further includes merging the plurality of woven microchannel tubes within a first and second end region arranged on the central region for producing a first and second end portion having a circular cross-section. The method further includes gluing the plurality of woven and merged microchannel tubes within the first and second end region and shortening the plurality of weaved, merged, and glued microchannel tubes within the first and second end region.