Indirect Charge Air Cooler S-Shaped Tab Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing indirect charge air coolers for internal combustion engines face challenges with solder-plated side parts, where the soldering process is complicated due to external solder plating, leading to manual removal issues and risk of crack formation from high pressure swings.
Innovation Solution
A heat exchanger design featuring a double-bent S-shaped tab on the side parts with one section soldered externally for easy soldering and the other internally for reinforcement, allowing for contact pressure without soldering to a frame, and a press-fit connection for enhanced stability and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If solder plating is applied to the outside of the side part for easy soldering, then soldering to the frame part is simplified, but the soldering frame may be soldered to the side part requiring manual removal
Solution Approach 1:
The side part is segmented into multiple regions with different solder plating configurations. The first region has solder plating on the outside surface for easy soldering to the frame part, while the second region has solder plating only on the inside surface, creating a solder-free external surface that prevents frame soldering and eliminates the need for manual removal.
2Strength
If high pressure is applied during soldering to ensure reliable connection, then soldering strength is improved, but crack formation occurs on the outer edges of side parts
Solution Approach 1:
Different regions of the side part have different properties: the first region has external solder plating for strong soldering connections, while the second region has internal solder plating only, creating a solder-free external surface that is more resistant to crack formation under pressure swings.
3Weight of stationary object
If the side part thickness is reduced to save material and weight, then material usage and weight are reduced, but the structural stiffness of the side part decreases
Solution Approach 1:
Instead of increasing thickness in the vertical dimension, the invention adds a horizontal dimension by providing a reinforcement element (second tab section) that extends from the side part. This reinforcement element provides additional structural stiffness without increasing the weight, as it is formed from the same material and represents an efficient use of material in a different spatial direction.
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 simplifies the soldering process, reduces the risk of frame soldering and crack formation, and provides cost-effective, weight-neutral production with increased stiffness and reduced thickness, facilitating efficient assembly and operation.
Implementation Method 1
a first tab section (10) solder-plated on the outside... a soldering for example with a frame part (7) can be easily achieved
Implementation Method 2
tubes (3) which form a first channel system for a first fluid flowing in a first flow direction (4)... a second channel system for a second fluid that is fluidically separated from the first channel system
Implementation Method 3
tubes (3) which form a first channel system for a first fluid... heat exchanger designed as charge air cooler
Data Source
AI summary
A heat exchanger, e.g., an indirect charge air cooler for an internal combustion engine, is disclosed. The heat exchanger includes a plurality of tubes that provide a first channel system for a first fluid, and a second channel system for a second fluid disposed between the plurality of tubes that is fluidically separated from the first channel system. Two opposite side parts for fluidically bounding the second channel system are provided, between which the plurality of tubes are arranged. At least one frame part is soldered together with a respective outer edge of the two side parts. The outer edge of a side part includes a tab bent over S-shaped as edge reinforcement with a first tab section solder-plated on an outside and a second tab section solder-plated on an inside. The frame part has an S-shaped cross section with a first receptacle that receives the first tab section.