Brazed Heat Exchanger Fluid Connection for Precise Leak-Safe Assembly
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Solution Overview
Problem
Existing heat exchanger fluid connections face challenges with costly and complex manufacturing processes due to the need for additional components like o-rings for sealing, and brazing methods can result in poor braze joints and fluid leakages from improper handling and positioning.
Innovation Solution
A brazed fluid connection design featuring a cylindrical extension with protrusions that securely engage with a flange on the heat exchanger's top plate, providing precise positioning and a metallurgical joint for secure attachment, using a braze alloy to create a strong bond during the brazing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a fluid connection is mechanically joined to the heat exchanger, then the connection can be assembled, but additional components like o-rings are required which increase cost and create potential leak locations
Solution Approach 1:
The patent combines the sealing function and mechanical connection function into a single integrated brazed joint. The extension is brazed directly to the heat exchanger core, eliminating the need for separate o-rings or gaskets. This merging of functions reduces component count, lowers cost, and eliminates potential leak locations while maintaining both assembly capability and fluid seal reliability.
2Manufacturing precision
If the fluid connection is expanded into the heat exchanger prior to brazing, then positioning is secured, but manufacturing cost and complexity increase and deformations occur
Solution Approach 1:
The extension is pre-formed with an integrated shoulder feature during the extension manufacturing process, before assembly. This preliminary action incorporates the positioning stop directly into the extension geometry, eliminating the need for separate expansion operations or additional positioning components. The result is precise positioning control without increasing manufacturing process complexity or causing deformations.
3Device complexity
If the fluid connection is brazed directly without expansion, then manufacturing is simpler, but the connection may be displaced during handling resulting in poor braze joints
Solution Approach 1:
The shoulder feature acts as an intermediary element that facilitates proper positioning during assembly. As the extension is inserted into the heat exchanger core, the shoulder makes contact with the core's internal surface first, establishing correct positioning before the extension is fully inserted. This intermediary positioning mechanism ensures consistent, high-quality braze joints while maintaining manufacturing process simplicity.
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 design enhances the reliability and cost-effectiveness of heat exchanger connections by ensuring precise positioning and a secure braze joint, reducing the risk of fluid leakages and manufacturing complexity.
Implementation Method 1
Braze alloy can be provided within the gap between the inner wall of the flange and the outer surface of the extension in order to create a metallurgical joint between the extension and the inner wall of the flange
Implementation Method 2
the melted braze alloy from the inner wall of the flange can wet against the outer surface of the extension and can re-solidify to form the braze joint
Implementation Method 3
The heat exchanger can be heated within a braze furnace in order to melt that clad layer
Implementation Method 4
The extension can be provided with a series of protrusions that extend outwardly from an outer surface of the extension. At least one of the protrusions, and sometimes more than one of the protrusions, can engage against the inner wall of the flange
Data Source
Figure 1~2
Figure 3~6
AI summary
A brazed fluid connection for a heat exchanger can include an extension arranged at one end that inserts into an aperture provided within a top plate of the heat exchanger. The top plate can be provided with a flange that extends around a periphery of the aperture, and a shoulder adjacent to the extension can be disposed against that flange. The extension can be provided with a series of protrusions that extend outwardly from an outer surface of the extension. At least one of the protrusions can engage against the inner wall of the flange, and a braze joint is present between the inner wall of the flange and the extension.