Zigzag Plate Heat Exchanger for Flat-Surface Thermal Contact
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Solution Overview
Problem
Conventional heat exchanger manufacturing methods result in non-flat main surfaces, leading to inefficient heat exchange due to convex-concave shapes, which can either hinder direct contact or require excessive heat conducting materials for indirect contact.
Innovation Solution
A heat exchanger manufacturing method involving a zigzag metal plate with mountain and valley portions, where the zigzag plate is easier to deform than the other plates, allowing for the formation of flat surfaces by pressure-induced widening of flow paths between the plates, enabling efficient heat exchange without the need for costly molds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional heat exchanger manufacturing methods are used, then heat exchangers can be produced, but the main surfaces become non-flat with convex-concave shapes
Solution Approach 1:
The zigzag metal plate is prepared in advance with a pre-formed zigzag shape before assembly. This preliminary shaping allows the plate to automatically form flow paths when expanded, eliminating the need for complex post-manufacturing surface finishing operations and achieving flat surfaces without additional manufacturing steps.
Solution Approach 2:
The manufacturing method changes the physical state and dimensions of the zigzag metal plate by applying expansion force. The plate transitions from a compact zigzag configuration to an expanded flat configuration, altering its shape parameter from convex-concave to planar surface, thereby achieving the desired surface flatness.
2Ease of manufacture
If heat exchangers with convex-concave surfaces are used, then manufacturing is simpler, but heat exchange efficiency decreases due to reduced contact area
Solution Approach 1:
The zigzag metal plate is pre-formed with a zigzag configuration that, when expanded, creates a flat surface. This preliminary shaping enables the plate to achieve optimal contact surfaces for heat exchange while maintaining manufacturing simplicity, as the flat surface is formed during the expansion process rather than requiring post-processing.
Solution Approach 2:
The expansion process transforms the zigzag metal plate from a compact state with reduced surface contact area to an expanded state with increased flat surface area. This parameter change directly improves heat exchange efficiency by maximizing the contact area between the heat exchanger and the target object.
3Reliability
If heat conducting material is used to fill concave portions, then heat exchange efficiency improves, but material usage and cost increase
Solution Approach 1:
The expansion process fundamentally changes the surface geometry parameter of the zigzag metal plate from convex-concave to flat. By eliminating the concave portions through expansion rather than filling them with heat conducting material, the method reduces material usage and associated costs while maintaining heat exchange efficiency.
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 method produces heat exchangers with flat surfaces that facilitate efficient heat transfer, reducing material usage and manufacturing costs while enhancing contact area for improved thermal performance.
Implementation Method 1
a fluid is supplied under pressure into the first through-hole and the second through-hole respectively, the regions of the third metal plate, which are among the regions that structure the respective first flow paths and second flow paths, are selectively pushed so as to widen
Data Source
AI summary
A heat exchanger manufactured by a heat exchanger manufacturing method of the present disclosure has a first metal plate and second metal plate, and a zigzag metal plate including a third metal plate formed in a zigzag shape. The zigzag metal plate has plural mountain portions joined to the first metal plate and plural valley portions joined to the second metal plate. The third metal plate deforms easily. The method includes: preparing a layered plate by layering the first metal plate, the third metal plate and the second metal plate in this order; joining the first metal plate and the third metal plate at regions of the layered plate that correspond to the mountain portions; and joining the second metal plate and the third metal plate at regions of the layered plate that correspond to the valley portions.