Systems and methods for assembling liquid desiccant air conditioner panels using flexible alignment features

1. A method of assembling a multilayer panel for use in a heat exchanger, the method comprising:

positioning a frame on a work platform, the frame having two header sections and a middle section, the middle section defining a heat transfer fluid area and each header section defining a frame alignment feature;

positioning a heat exchange sheet on the frame across the middle section and each header section, the heat exchange sheet having two sheet alignment features each corresponding to one of the frame alignment features, wherein at least one of the two sheet alignment features includes a flexure formed within the heat exchange sheet, the flexure defining a flexible region on the heat exchange sheet;

inserting an alignment pin of the work platform into each of the corresponding frame and sheet alignment features; and

welding the heat exchange sheet to the frame.

2. The method of claim 1 , wherein each of the header sections of the frame defines a header area and the heat exchange sheet has two series of apertures, wherein each of the two series of apertures are located proximate one of the sheet alignment features, wherein positioning the heat exchange sheet on the frame comprises aligning each of the series of apertures with one of the header areas.

3. The method of claim 2 , wherein welding the heat exchange sheet to the frame comprises forming a middle weld enveloping the heat transfer fluid area, the middle weld located between the two series of apertures.

4. The method of claim 3 , wherein welding the heat exchange sheet to the frame comprises forming the middle weld and the two outer welds, each of the outer welds enveloping a corresponding one of the header areas and the corresponding series of apertures.

5. The method of claim 4 , wherein welding the heat exchange sheet to the frame comprises forming the middle weld and the two outer welds in a single welding operation.

6. The method of claim 2 , wherein inserting the alignment pin of the work platform into each of the corresponding frame and sheet alignment features operates to control alignment between each series of apertures and the corresponding header area during the welding of the heat exchange sheet to the frame.

7. The method of claim 2 , further comprising attaching a membrane to the heat exchange sheet.

8. The method of claim 7 , wherein attaching the membrane to the heat exchange sheet is performed prior to welding the heat exchange sheet to the frame.

9. The method of claim 7 , wherein attaching the membrane to the heat exchange sheet comprises forming heat seal lines adjacent each of the series of apertures to define a desiccant channel extending between and connected to the two series of apertures, wherein alignment between the heat seal lines and the series of apertures is controlled by each of the alignment pins received within the corresponding sheet alignment features.

10. The method of claim 9 , wherein attaching the membrane to the heat exchange sheet further comprises forming discrete heat seals between the two series of apertures.

11. The method of claim 10 , wherein the heat seal lines and the discrete heat seals are formed in a single heat sealing operation.

12. The method of claim 1 , further comprising controlling tolerance stack between the frame and the heat exchange sheet using the flexure formed within the heat exchange sheet and a flexure of a corresponding frame alignment feature formed within the frame.

13. The method of claim 1 , wherein the heat exchange sheet and the frame each include a thermoplastic material.

14. A method of assembling a multilayer panel for use in a heat exchanger, the method comprising:

positioning a frame on a work platform, the frame having two header sections and a middle section, the middle section defining a heat transfer fluid area and each header section defining a frame alignment feature;

positioning a heat exchange sheet on the frame across the middle section and each header section, the heat exchange sheet having two sheet alignment features each corresponding to one of the frame alignment features;

attaching a membrane to the heat exchange sheet;

inserting an alignment pin of the work platform into each pair of corresponding frame and sheet alignment features; and

welding the heat exchange sheet to the frame,

wherein each of the header sections of the frame defines a header area and the heat exchange sheet has two series of apertures, wherein each of the two series of apertures are located proximate one of the sheet alignment features, wherein positioning the heat exchange sheet on the frame comprises aligning each of the series of apertures with one of the header areas,

wherein attaching the membrane to the heat exchange sheet comprises forming heat seal lines adjacent each of the series of apertures to define a desiccant channel extending between and connected to the two series of apertures.

15. The method of claim 14 , wherein attaching the membrane to the heat exchange sheet further comprises forming discrete heat seals between the two series of apertures.

16. The method of claim 15 , wherein the heat seal lines and the discrete heat seals are formed in a single heat sealing operation.

17. The method of claim 14 , further comprising controlling tolerance stack between the frame and the heat exchange sheet using flexures at each of the pairs of corresponding frame and sheet alignment features.